Patent ID: 12246914

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter with reference to example embodiments thereof with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. These example embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Features from one embodiment or aspect can be combined with features from any other embodiment or aspect in any appropriate combination. For example, any individual or collective features of method aspects or embodiments can be applied to apparatus, product, or component aspects or embodiments and vice versa. The disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and the appended claims, the singular forms “a,” “an,” “the,” and the like include plural referents unless the context clearly dictates otherwise. In addition, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to manufacturing or engineering tolerances or the like.

As used in the description and the appended claims, the phrases “unit load device” (ULD) or “air cargo container,” is defined as containers used to load luggage, freight, mail, and the like on aircraft including wide-body aircraft and narrow-body aircraft. While the containers described herein are directed to ULDs for use with aircraft, it is contemplated that cargo containers including the removable brackets may be used in other transportation vehicles such as trucks, trailers, ships, or trains such that the described use with aircraft should not be seen as limiting.

Referring now toFIG.1, an air cargo container is provided in accordance with embodiments of the present disclosure and is referred to generally as cargo container10. The cargo container10includes a base20, sidewalls30, a backwall40, a door50, and a topwall60that are secured to one another and cooperate to define an interior70of the cargo container10. As shown, a top surface222of a top plate220of the base20is accessible from the interior70of the cargo container10. The cargo container10may include additional structures and/or insulation that prevent access to the top surface222of the top plate220. For example, a cargo container10may include active cooling/heating equipment, insulation, shelving, or other structures that prevent access to the top surface222. In addition, when the cargo container10is loaded, the top surface222of the top plate220may be in accessible due to cargo obscuring portions of the top surface222.

The container10may be designed to hold 3500 pounds with a vertical safety factor of 5 such that the base20may be designed to safely hold 17,500 pounds. There are other forces that may require the base20to sustain 9,800 pounds in one or more other directions. The high load specification and design strength of the base20may be critical for the container10. In addition, air cargo containers are transported on and off airport by forklifts, e.g., standard forklifts, that engage and lift the base20of the container10to lift and move the container10. It is common for the base20and other parts of an air cargo container10to be damaged from erratic driving practices including, but not limited to, being dropped, colliding with other air cargo containers, pierced by forklift tines, rolled or tipped over, colliding with other parts of a forklift or other vehicles. When an air cargo container is damaged, it may become unairworthy and require repair to return it to airworthiness.

The sidewalls30, backwall40, door50, and the topwall60may have a variety of constructions. While the sidewalls30, backwall40, door50, and the topwall60are shown as rigid structures, one or more of the sidewalls30, backwall40, door50, and the topwall60may be flexible. For example, the door50may be a fabric door that selectively closes or seals an opening52of the cargo container10.

With additional reference toFIGS.2and3, the base20is detailed in accordance with embodiments of the present disclosure. The base20includes the top plate220, a bottom plate230, and risers242,244,246,248extending between the top plate220and the bottom plate230. The risers include a front riser242, a back riser244, and side risers246,248. At least the front riser242and the back riser244define holes243,245that provide access for forklift tines to pass through the base20and allow the base20, and the cargo container10to be lifted by a forklift or other lifting apparatus. In some embodiments, the side risers246,248also include holes247,249that provide access for forklift tines to pass through the base20and allow the base20, and the cargo container10to be lifted by a forklift or other lifting apparatus. The holes243,245,247,249may include impact plates241on the sides of the holes243,245,247,249to protect the sides of the holes243,245,247,249. The impact plates241may wrap around the sides of the respective riser242,244,246,248and be positioned on an outside surface and an inside surface of the respective riser242,244,246,248. The risers242,244,246,248may include a top flange252and/or a bottom flange254to join with the top plate220or the bottom plate230respectively. The risers242,244,246,248maybe welded, riveted, and/or joined with fasteners to the top plate220and/or the bottom plate230respectively.

The base20includes a plurality of brackets270disposed between the top plate220and the bottom plate230. The brackets270are secured to the top plate220and the bottom plate230to provide compressive strength to the base20, e.g., to resist a downward force from the top plate220towards the bottom plate230. The brackets270also provide shear strength to the base20such that the brackets270prevent sliding of the top plate220relative to the bottom plate230in directions parallel to planes of the top plate220and the bottom plate230.

Referring now toFIGS.4and5, the brackets270are arranged and oriented between the top plate220and the bottom plate230to allow for the passage of tines of a forklift through the base20. For example, the holes243and245and the brackets270define a first channel253and a second channel255that extend through the base20perpendicular to the risers242and244. The holes247and249and the brackets270define a third channel257and a fourth channel259through the base20perpendicular to the risers246and248.

The brackets270are oriented to deflect impacts from forklift tines such that the forklift tines are directed into the respective channel253,255,257,259. It will be appreciated that when a forklift engages a base20, it is rare for the forklift to be aligned with the base20such that the tines of the forklift will pass through a channel of the base without contacting one of the brackets270. As such, the brackets270are oriented such that when a tine of the forklift enters a respective hole of the base, the tine will impact one or more of the brackets270. As the tine impacts the brackets270, the brackets deflect the tine such that the tine is directed towards the channel or the base20is rotated such that the tine is directed into the respective channel. The orientation of the brackets270may deflect a substantial amount of force from the tines such that the brackets270are capable of withstanding multiple impacts from tines. However, at times, the force of the tine impacting the bracket270may break or damage a bracket270.

With reference toFIG.7, the brackets270are orientated such that the brackets270that may be impacted on a face by a tine of a forklift such that the face directs the tine towards a respective channel with the tines passing subsequent brackets270that may direct a tine coming in from the opposite hole into the respective channel. The orientation of the brackets270may reduce potential damage to the bracket when impacted by the tine and/or prevent the tine from impacting another one of the brackets270.

For example, when a tine enters channel253through the opening243, the tine will pass brackets270aand270e. If the tine is out of alignment with the channel253, the tine may impact a face of bracket270bor270fUpon impact with the face of the respective bracket270b,270f, the orientation of the bracket270b,270fdirects the tine into alignment with the channel253and towards the opening243in the opposite riser. In addition, the brackets270b,270fmay be orientated to minimize the impact force that is absorbed by the bracket270b,270f. When the tine passes brackets270b,270f, the tine will also clear brackets270c,270g. The tine may contact bracket270d,270hbefore exiting through the opening243which direct the tine towards the other opening243.

Referring now toFIG.8, the construction of a bracket270is described in accordance with embodiments of the present disclosure. The bracket270includes a foot272, a vertical body274, and a head276. The foot272is substantially perpendicular to the body274and extends in a first direction away from the body274. The head276is substantially perpendicular to the body274and extends in a second direction away from the body274that is opposite the first direction such that the bracket270has a Z-shaped profile. In embodiments, the first and second direction may be the same direction such that the bracket270has a C-shaped profile. The bracket270may be formed from a single sheet of material that is folded or bent to the Z-shaped profile or other profile. In embodiments, the foot272and/or the head276may extend from the body274at an angle other than perpendicular. For example, the foot272and/or the head276may extend from the body274at an angle in a range of 30 degrees to 90 degrees, e.g., 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, or 90 degrees. A foot272and/or head276that extends at angles other perpendicular may allow the brackets270to withstand additional shear forces compared to a perpendicular angle.

The foot272of the bracket270is fixed to the bottom plate230by one or more rivets273. In some embodiments, the foot272is fixed to the bottom plate230by one or more fasteners273, e.g., rivets, screws, bolts, etc. As detailed below, the fasteners273may be rivets273that may fix the foot272to the bottom plate230such that the foot272can be removed by drilling out the rivets273. The rivets273may be blind rivets such that the rivets273do not extend above a top surface222of the top plate220and/or the bottom surface232of the bottom plate230.

The head276is moveably secured or retained to the top plate220by a latch280. The latch280has a first layer282and a retainer284. The first layer282is fixed to the top plate220by one or more rivets273. The rivets273may fix the latch280to the top plate220. In embodiments, the latch280is fixed to the top plate220by one or more fasteners. The latch280is positioned such that the retainer284defines a receiver286with the top plate220. The first layer282and the receiver286may be shaped such that the receiver286complements the shape of the head276. For example, the head276may include a slanted surface277that mates with a slanted surface287of the receiver286. The cooperation of the slanted surfaces277,287may improve securement of the head276in the receiver286. The low profile of the latch280may prevent damage to the latch280when the body274of the bracket270is impacted. In embodiments, the first layer282of the latch280has a thickness that is substantially equal to the thickness of the head276of the bracket270such that the receiver286can receive and release the head276of the bracket. The bracket270may be oriented within the base20such when the body274is contacted or impacted from a predicted direction, as detailed above with respect toFIG.7, the head276is directed into the latch280such that the latch280retains the head276and resists a force of the impact for the top of the bracket270.

The construction of the bracket270allows for the bracket270to be replaced without access to the top surface222of the top plate220of the base20. As such, the bracket270is replaceable without disassembly or removal of insulation or other structures from the cargo container10. In some embodiments, the bracket270can be replaced without unloading or opening of the cargo container10such that the integrity and/or a temperature within the cargo container10can be maintained during the replacement of the bracket270.

It will be appreciated that in it may be possible to construct the brackets270such that the brackets270will not be damaged when impacted by a tine. However, as weight is of importance with respect to cargo containers and especially air cargo containers, that providing a bracket that is strong for normal use and allows for replacement when damaged is preferred to a heavy bracket that may survive more significant impacts. The brackets270are designed such that the body274is designed as the failure point of the bracket270such that when a bracket270is damaged, the latch280is undamaged. The low profile of the latch280may reduce a possibility of damage to the latch280when the body274is damaged.

Referring now toFIGS.9-15, a method1000of replacing a damaged bracket270of a cargo container10in accordance with the present disclosure. With initial reference toFIG.10, a damaged bracket270is identified within the base20(Step1010). For example, the bracket270fmay be damaged from a forklift tine that entered the opening243or the opening247and impacted the bracket270fIt should be appreciated that the method1000may be used to replace any of the brackets270of the base20.

With particular reference toFIG.11, with the damaged bracket270identified, the base20is positioned in a manner to allow access to a bottom surface232of the bottom plate230(Step1020). To allow access to the bottom surface232, the base20may be lifted, e.g., by a forklift or other lifting means, such that a technician can access the rivets273of the damaged bracket270through the bottom surface232of the bottom plate230. In some embodiments, the base20may be positioned over a tunnel or pit that allows for access to the bottom surface232by a technician standing underneath the base20with the base fully supported. With access to the bottom surface232of the bottom plate230, a technician drills out the rivets273or otherwise removes the rivets273or other fasteners fixing the foot272of the bracket270to the bottom plate230(Step1030). With the rivets273removed from the foot272, the foot272of the bracket270is unsecured or released from the bottom plate230.

With the foot272unsecured from bottom plate230, the bracket270is removed from the base20through the opening243or the opening247as shown inFIG.12(Step1040). The bracket270may be removed by reaching through the opening243or opening247and grasping the body274of the bracket270. As the only rivets273or fasteners fixing the bracket270in the base20were the rivets273in the bottom plate230and the foot272, the bracket270is free once the rivets273in the bottom plate230and the foot272are removed. The head276may need to be persuaded to remove the head276from the receiver286(FIG.8). For example, the head276may become wedged or jammed into the latch280due to impacts to the body274of the bracket270. When the bracket270is free from the latch280, the bracket270can be withdrawn or removed from the base20through the closest opening, e.g., opening243,247. The bracket270may be rotated to withdraw the bracket270through the opening.

When the old, damaged bracket270is removed through the opening, the latch280remains fixed to the top plate220of the base200as shown inFIG.13. With the damaged bracket270removed, a new bracket270′ is passed through the opening and positioned within the base200as shown inFIG.14(Step1050). To position the new bracket270′ in the base200, a head276′ of the new bracket270′ is positioned within the receiver286of the latch280and a foot272′ of the new bracket270′ is positioned such that holes in the foot272′ are aligned with holes in the bottom plate230of the base200such that the foot272′ can be fixed to the bottom plate230. With the new bracket270′ positioned in the base200, the foot272′ of the new bracket270′ is fixed to the bottom plate230as shown inFIG.15(Step1060). For example, the foot272′ may be fixed by using blind rivets passed through the holes in bottom plate230and the holes in the foot272′ to secure the foot272′ to the bottom plate230. The use of blind rivets may allow for the securement of the foot272′ without any portion of the rivets extending below a bottom surface232of the bottom plate230. In some embodiments, other types of fasteners may be used to fix the foot272′ to the bottom plate230.

The method1000detailed above may be performed by only accessing the bottom plate230of the base200. More specifically, the method1000may be performed without access to the top surface222of the top plate220. By allowing replacement of a bracket270from only the bottom plate230, the bracket270may be replaced without disassembly of a cargo container or without opening a cargo container such that cargo can remain in the cargo container during replacement. In some embodiments, a support may be replaced without breaking a seal of the cargo container to maintain an integrity of the interior of the cargo container.

While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Any combination of the above embodiments is also envisioned and is within the scope of the appended claims. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope of the claims appended hereto.