MODULAR RACK SYSTEM AND COMPONENTS THEREFOR
Embodiments of the invention may encompass a container storage system having a modular storage rack including framing elements each having a locking component of at least one end thereof and a counterpart locking component on another end; each locking element being engagable with each other; and wherein the storage rack is assembled to maximize storage capacity within the shipping container. It may also include a modular array having at least one elongated framing element with at least one key on at least one end thereof having an elongated rotatable member having at least one flange extending radially therefrom; at least one other elongated framing element having at least one opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/794,183, filed Apr. 21, 2006.
BACKGROUNDThe invention relates to the field of racks for shipping and storing industrial products. More particularly, the invention relates to modular shipping and storage racks and components therefor.
As is well known to those working in the shipping and storage industries, there is a veritable plethora of rack systems used for the transport and/or storage of countless numbers of items ranging from fasteners, to automobiles, to heavy industrial equipment and so forth. Generally, such rack systems are designed for a particular purpose, such as the transport or storage of a particular type of item, be it tools, gears, bumpers, wheels, etc. As a rule, a rack system designed for a particular purpose is not readily adaptable for another purpose. For example, rack systems optimized for storage make poor shipping containers, as they are generally built to take primarily downward loads. In addition, such systems ordinarily provide little protection to the merchandise from the jolts and jarring that are inherent to stevedoring operations. On the other hand, rack systems optimized for shipment of merchandise generally make poor storage devices. To the applicant's knowledge, the design of rack systems which accommodate a wide range of products of varying size in both shipping and storage functions is still in its infancy.
What is needed is a modular rack system, the configuration of which can be readily modified to accept a variety of merchandise, and which can be ganged, expanded, contracted, or fitted with accessories, as needed. Additional desirable qualities would be that the modular rack system, when assembled and loaded, be easily moved by forklift and readily fitted with lift cables, and that when no longer needed for storage or transport purposes, it be easily disassemblable, stowable, and transportable.
Further, a significant problem in shipping is the need, in a more security conscious world, of inspecting or testing articles in shipping containers entering or leaving a county's ports. Generally, articles are packed densely into shipping containers to maximize the return on the expense of renting the container. These articles are typically stacked box on box, without any rack or internal storage container. Consequently, it is very time consuming and expense to inspect or test articles in these containers, due to the need to remove the articles box by box for inspection. A further advantage of the invention would be its adaptation for use within existing shipping containers, allowing ease of access to merchandise for inspection or testing, without the need to unpack the container.
SUMMARY OF THE INVENTIONEmbodiments of the invention may encompass a shipping container storage system having a modular storage rack that includes a plurality of framing elements, each of the framing elements having a locking component of at least one end thereof and a counterpart locking component on another end thereof, each of the locking component and the counterpart locking element being engagable with each other to connect said framing elements together; and wherein the modular storage rack is assembled in a configuration to maximize storage capacity within the shipping container.
A further embodiment of the invention may include a modular array having at least one elongated framing element; at least one key on at least one ends of the framing element, the key having an elongated rotatable member and at least one flange extending radially from the elongated rotatable member; at least one other elongated framing element; at least one opening on the other elongated framing element, the opening being shaped to receive the key; wherein the framing elements are arranged to form the array and the key and the opening are used to engage the framing elements by inserting the key into the opening and rotating the key.
BRIEF DESCRIPTION OF THE DRAWINGSFor a better understanding of the invention, together with other objects, features and advantages, reference should be made to the following detailed description which should be read in conjunction with the following figures wherein like numerals represent like parts.
For simplicity and ease of explanation, the invention will be described herein in connection with various exemplary embodiments thereof. Those skilled in the art will recognize, however, that the features and advantages of the invention may be implemented in a variety of configurations. It is to be understood, therefore, that the embodiments described herein are presented by way of illustration, not of limitation.
At the outset, and as shown in the drawing and in particular
It should be evident that a variety of rack array configurations may be formed by combining coupler blocks 11 and beams of various lengths 12 in a virtually limitless number of ways.
Referring now to
The central connector assembly, which may be fabricated as a welded-up unit from a metal such as steel or titanium, may extend into each of the six apertures of the coupler block 11. If a coupler block is fabricated in such a manner, the square tube 35 visible in aperture 14A may be such an extension. If a coupler block 11 is cast or machined as a single unit, then the body 34 and the entire central connector assembly, which includes square tube 35, may simply be part of a single casting. In any case, each square tube extension 35 may have an anchoring hole 36 therethrough for receiving a retaining pin 15. This anchoring hole 36 may be aligned with the pin insertion hole 16 through the coupler block body 34.
The beams 12 of a rack system array may be tied to this central connector assembly. If the coupler block 11 is formed as a composite item, the coupler block body 34 may be formed from any suitable, durable material, such as a plastic, a lightweight metal such as aluminum or magnesium or alloys thereof, or the like. Useful plastic materials include ABS resins, epoxy resins, high-density polyethylene, polyalkylenes, polycarbonates, and polyurethanes used either alone or in combination with reinforcing high-tensile-strength fibers, such glass or graphite. When made of a moldable material, the coupler block body 34 may be formed by any suitable molding process known to the skilled artisan. It is to be understood that it is not the particular material or the method by which it is molded that is a critical factor, but rather that the body be formed from a suitable durable material. The coupler block body 34 may theoretically have any desired three-dimensional polygonal configuration (e.g., pyramidal, pentahedral, cubic, octahedral or decahedral). A cubic configuration permits rectangular rack arrays. As will be noted each of the six faces 13 of the coupler block body 34 may have a boss 37 which surrounds the aperture 14. The boss 37 imparts additional strength to the coupler block body 34 without a corresponding increase in total weight.
Referring now to
Referring now to
The welded-up central connector assembly 51 may be formed from hollow interior cube 52. One square tube extension 35 may be welded to each of the six faces of this interior cube 52. In the center of each region of a face of the interior cube 52 may be a threaded hole 41. The threaded holes 41 in opposing sides not only permit passage of a supporting cable through the center of the coupler block 11, but also provide a threaded anchor for a bolt which may be used to attach a shock-absorbing foot 18 to any of the six faces 13 of the coupler block 11. Each edge of the interior cube 52 may have a fin 54 welded thereto. The eight fins 54 (one for each edge of the cube) may be imbedded within the material from which the coupler block body 34 is cast, and assist in maintaining the welded-up central connector assembly 51 firmly anchored within the coupler block body 34.
Referring now to
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A valve 95 may be incorporated in the foot 18, which allows the chamber 94 to be pressurized with air or some other appropriate gas to accommodate loads of varying weights. A hollow-core mounting bolt 96 may be used to secure the foot 18 to a coupler block 11. The internal chamber 94, particularly when inflated, defines a compressible shock absorber or bumper which not only protects an attached coupler block 11, but also protects the entire rack array 10 and the merchandise stored therein from excessive jarring and shock. In order to determine the shock loading to which the rack array 10 has been subjected during transit, loading and unloading, an electronic shock recorder may be installed on the rack assembly in any suitable position. It is to be appreciated that in assembling a rack, such as that disclosed in
Referring now to both
It is to be appreciated that electronic tagging devices may be associated with the modular rack system for identification, inventory control and shipment routing. For example, one or more electronic modules may be attached to the rack system. A radio-frequency identification tag having rewritable on-board memory may be used for shipment identification, inventory control and shipment routing functions. A simpler electronic module might only provide a rewritable memory for storing an electronic inventory list and shipping manifest.
Referring now to
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It should now be fully appreciated that the design of the coupler block 11 and longitudinal beams 12 enables the erection of a virtually limitless variety of rack arrays using multiple coupler blocks 11 and a plurality of beams 12 of desired lengths. In addition, the new modular rack system is ideally suited to computer-controlled “pick and place” robotic assembly. The modular rack system herein described also accommodates electronic monitoring of shock forces to which the system is subjected.
Further embodiments of the invention are illustrated in
As is clear from the above descriptions, the sub-set rack would not add substantial weight to the gross container wait. For example, the rack could be steel frame with aluminum side walls. Moreover, most container loads are filled to capacity based upon volume long before the maximum weight limit of the container is reached, allowing significant margin for any additional weight from the rack system of the invention.
An illustration of an embodiment of the invention along these lines is shown in
In such an embodiment, or others, a further type of connector mechanism may be used. An example of this is illustrated in
The key may include a hole in the substantially cylindrical element, allowing a rod or other elongated abject to be inserted into the hole for rotating the key. In one embodiment, the framing element may have an opening across a face thereof to allow such bar to be inserted to the key.
The key may be mounted to the framing element, for example, using a mounting screw as illustrated. Of course, those of ordinary skill in the art that the key may be mounted using any number of conventional means and configurations. Also, those of ordinary skill in the art will appreciate that framing elements may also be connected at a corner or angle by including a key extending at an angle from the end or side of the framing element, and similarly an angled opening on another framing element.
Wheels or rollers may be included, along with a tow plate, allowing the racks to be wheeled in and out of the container. Lifting rails for forklifts, pallet jacks, etc. may also be included to the remove the racks in that manner.
An omni type coupler may also be incorporated, allowing elements to be coupled both horizontally and vertically in one or more directions.
In the above manner, embodiment of the invention may be used to solve the port embarkation inspection problem. The invention also allows faster packing of containers, as racks may even be preloaded at the factory or other source.
The embodiments that have been described herein, however, are but some of the several which utilize this invention and are set forth here by way of illustration but not of limitation. It is obvious that many other embodiments, which will be readily apparent to those skilled in the art, may be made without departing materially from the spirit and scope of the invention as defined in the appended claims. Changes and modifications to the system may be made without departing from the scope and spirit of the invention as hereinafter claimed. For example, other means for securing the beams to the coupler blocks may be employed. Similarly, other types of coupler blocks and beams which similarly cooperate may also be used.
Claims
1. (canceled)
2. A modular array, comprising:
- at least one elongated framing element;
- at least one key on at least one ends of said framing element, said key having an elongated rotatable member and at least one flange extending radially from said elongated rotatable member;
- at least one other elongated framing element;
- at least one opening on said other elongated framing element, said opening being shaped to receive said key;
- wherein said framing elements are arranged to form said array and said key and said opening are used to engage said framing elements by inserting said key into said opening and rotating said key.
3. The modular array of claim 2, wherein said opening further comprises an inclined surface around at least a portion thereof, causing said flange to compress said framing elements together when said key is rotated.
4. A shipping container storage system comprising:
- a modular storage rack comprising:
- at least one elongated framing element;
- at least one key on at least one ends of said framing element, said key having an elongated rotatable member and at least one flange extending radially from said elongated rotatable member;
- at least one other elongated framing element;
- at least one opening on said other elongated framing element, said opening being shaped to receive said key;
- wherein said framing elements are arranged to form said array and said key and said opening are used to engage said framing elements by inserting said key into said opening and rotating said key; and
- wherein said modular storage rack is assembled in a configuration to maximize storage capacity within said shipping container.
5. A shipping container storage system comprising:
- a modular array comprising: a plurality of elongated beams, each beam having a pair of opposed ends, each end having a locking hole; a plurality of coupler blocks, each of which has a plurality of external faces, each face having an aperture for receiving an end of a beam, and each aperture having associated therewith a pin retaining hole and
- a locking mechanism associated with each aperture for releaseably locking the received end of a beam therein, said locking mechanism comprising a retaining pin which is removably insertable within said pin retaining hole, said retaining pin passing through the locking hole of the received end; an
- wherein said modular array is assembled in a configuration to maximize storage capacity within said shipping container.
Type: Application
Filed: Apr 23, 2007
Publication Date: Jan 10, 2008
Inventor: Richard Palmeri (North Palm Beach, FL)
Application Number: 11/739,088
International Classification: A47B 47/00 (20060101);