CONNECTORS FOR ASSEMBLING SHIPPING CONTAINERS
A series of connectors for connecting panels of a shipping crate or box together. The invention will allow the user to make a box from a kit. A set of uniquely shaped corner pieces that will accommodate the sides, top and bottom of the structure will be used and provide the framework for the finished product. Because of these corner pieces the finished crate or box will be as strong as a box that is made by a skilled carpenter. Intermediate reinforcement pieces are also disclosed.
A. Field of the Invention
This invention relates to the field of packaging and, more particularly, relates to apparatus for attaching panels of a package, box or container together to form an article shipping enclosure. The invention permits the easy formation of an extremely strong box in any size or shape in which to ship an item without undue cost or difficulty.
B. Prior Art
Articles that need to be shipped come in various shapes and sizes, and it is not uncommon to have odd-shaped items that need to be shipped. These types of odd-shaped items are difficult to ship because of their unique geometric structure. Currently a specific box or crate must be custom made to house the uniquely shaped item if the item does not fit into a pre-existing sized box. Custom manufacture of shipping boxes, whether of cardboard, wood or of any other material, is costly and time-consuming, both in terms of material and labor. Ordinarily a carpenter would need to make the box from wood, which may take hours, even with a skilled carpenter doing the work.
Conventional shipping crate building methods and apparatus result in exposed staples, screws and the like extending from either the inside or outside of the crate, which may damage the contents or injure a handler. As a result, many shipping outfits refuse to accept freight which is improperly crated, or which has been crated by methods, and using apparatus, which do not meet the strength and safety criteria of the shipper. Many individuals seeking to ship freight do not have the wherewithal to properly construct a crate which will meet the specifications of the shipper.
Even if the crate is insured prior to transit, it still must be inspected when it reaches its destination if it has been damaged during shipping to determine if it was indeed crated properly. If not, insurance coverage may be denied.
There are many prior art references directed to crate or box making kits, including collapsible plastic crates. A representative example of this type of device can be found at Sunus, U.S. Pat. No. 4,789,075.
Another example of a metal shipping crate can be found at Dunn, U.S. Pat. No. 6,726,041, and a returnable crate is found at Grigsby Sr., U.S. Pat. No. 6,585,126.
None of the prior art references use unitary box panel connectors to secure the various pieces that form the sides, top and bottom of the crate. The connectors permit the user the unique ability to form the structure in any shape or size to custom make a box or crate to fit specific shipping needs.
Therefore, a need exists to provide a simple apparatus for assembling shipping crates/packages/boxes and the like, which can be combined with crate/package/box side, top and bottom panels of any dimensions to construct shipping crates of any sizes and proportions.
It is, therefore, an object of this invention to provide a simplified shipping box and crate assembly kit, apparatus and method.
It is also an object of this invention to provide a simple apparatus for creating shipping boxes and crates of any sizes but which can withstand the rigors of typical freight handlers.
It is also an object of this invention to provide a cost efficient apparatus, system and method for constructing shipping boxes and crates.
These and other objects, features and advantages of the present invention will become apparent upon reading the following detailed description of the disclosed embodiments of the invention, in conjunction with appended drawings and claims.
BRIEF SUMMARY OF THE INVENTIONThis invention is directed to a device to make a crate or box specific to an individual's shipping needs. A set of connector pieces will be used to join the side, bottom and top panels of a box in order that the assembled box can support the weight of the cargo inside the box and also allow the box to retain its shape.
A box or crate will have a defined top, defined bottom, and defined sidewalls. With this invention, a set of corner pieces, or edge pieces, or any combination of the two, will be used to connect the panels so that an individual can custom make his or her box or crate to fit a specific need. The exact size of the box that will be made will depend on the dimensions of the sides, top and bottom of the box, and the size of the box that will be made using the connectors of this invention has essentially no limit. In fact, in certain circumstances it may be desirable to use any of the known banding techniques, wherein a metal or other high tensile strength strap is placed around four sides of the crate or box being assembled and pulled taut there around.
This is a device, that is a kit for making a uniquely shaped crate with which an individual can custom make a box or crate to fit and address those particular needs in a matter of minutes without the necessity of hiring a skilled craftsman. The finished crate or box will be as strong as the box or crate that is made by the skilled carpenter and will accommodate the item to be shipped. Additionally, the crate or box may be reusable depending on the condition of the box material after the box has been shipped. The box may also be made without tape.
A unique set of corner pieces are disclosed. Corner sections of each of the sides, top and bottom of the crate or box will fit into corresponding channels defined by the corner pieces. Fasteners to secure the sides, top and bottom of the structure to the corner and side connectors will also be provided. This may be accomplished with staples, screws, bolts or adhesive, to name a few examples.
Additionally, a set of reinforcing members or strips may also be used in the interior of the box (i.e. between corners along adjacent edges of the side and the top and bottom) to secure the sides to the top or bottom and provide additional support and strength for the box or crate. These reinforcing members may be custom made to fit a particular need by simply snipping or cutting off a desired length of reinforcing member and placing it/them in desired locations on the box or crate either alone (i.e. without the use of corner connectors) to supplement the corner connectors
This device is a kit to make shipping cartons or boxes specifically designed to ship any uniquely shaped items. Boxes to ship devices are common in the prior art. However, there are standard-sized boxes that are used to ship letters, posters, and the like. The difficulty arises when a uniquely shaped object must be shipped that does not fit one of the standard boxes that currently exist.
A carpenter or other skilled craftsman must be employed to make a specifically designed box in order to ship the item. This is, of course, costly in terms of labor and material. It would be helpful to have a kit from which individual boxes of virtually any size or proportions can be made using a plurality of standard corner and side connectors.
Additionally, because of security concerns, the interior contents of the box or crate may be visually examined by the shipper or government authority. It is important to easily gain access to the internal contents of the box or crate and then be allowed to reseal the box or crate. This kit will allow an individual to perform that particular function.
A typical shipping container or box suitable for use with the teachings of this invention is shown in
As depicted in
The top, bottom and side panels that will be used to form the box or crate will be inserted into these channels such as depicted in
Channels 12, 22 are defined by respective sidewalls 14, 16, and 24, 26. The channels of any particular configuration of edge or corner connector may be of different length. Also, outer sidewalls 14, 24 may be hinged or articulated to permit the use of adhesive strips or toher adhesive material 15 that is secured to the interior surface of the sidewalls 14, 24. Adhesive material 15, if in the form of an adhesive strip, is configured so that a non-adhesive backing strip is peeled back at the corner and then secured to the side, tops or bottom panel that forms the box.
The panels that form the box will be placed within the channels 12, 22. The material which the panels are formed of may be plastic, wood, steel, aluminum, cardboard, etc, and will be dictated by the item that is to be shipped as well as the cost of the panels and cost to ship the item. Additionally, the connector members may preferably be constructed of plastic, graphite, metal or any other suitable material. It must be strong enough to support and form the box while at the same time supporting any weight that is to be applied to the box. Although the corner pieces (and, optionally, the side pieces) are used to make the box or crate, the box or crate may be made without the use of tape.
The sides 4-7, top 2 and bottom 3 of the box or crate can be varied by cutting the sides, top and bottom to the length and width that is required by the user. Depending on the condition of the box material the box may be reusable.
Additionally, there may be other alternative embodiments of the side and corner connectors which will occur to those of skill in the art, and while the box or crate will have the general appearance of a crate or box the side and corner connectors vary such as depicted in the drawings.
The box is formed by placing any one of the corner connectors depicted in FIGS. 7D, 8D, 9D, 10D or 11A-11D, as an example, on the corners where the side panels 4, 5, 6 and 7 will be. Each box or crate will have a defined top and/or a defined bottom as well as three, four or more sides. The sides do not necessarily need to be of equal width or length.
The corner connectors are placed on the corner of side, top and bottom panels 2-7 such that corresponding corners of the sides, top, and bottom of the box will be placed in the channels 12, 22 and 32. Additionally, there may be one or more adhesive reinforcing strips 15, 45, 115 & 135 placed on the inside surface of the sidewalls 14/24, 44/54, 74/84, 102 and 134 (or on the corresponding flexible members 25, 55, 85, 125 and 145) to secure the top to the sides and the bottom to the sides of the box. The reinforcing strips may be made by simply cutting the strip to a specific length and inserting the strip into the sidewall.
Additionally, the panels 2-7 may be secured within the respective channels by fasteners F such as staples, nails, screws or the like as depicted in
Additionally, the sides may be secured with adhesive for additional support.
Referring now more specifically to the drawings,
As can be seen in
Turning now to
One or more fasteners may be placed through top or bottom panels 2, 3 and through shoulder 110 into space 112, where they are protected by barrier wall 118 from contacting the item within the shipping box, as shown in
The connector of this embodiment includes a channel 222 defined by outer and inner sidewalls 224, 226, a top sidewall 230 adapted to receive a crate panel in coplanar fashion thereon, and a barrier wall 228. In use, a first panel will be inserted into channel 222, a second panel will be placed coplanar with top sidewall 230, and fasteners placed there through and through sidewalls 224, 226 and 230 and 232. Sidewalls 226 and 232, along with barrier wall 228, define a space 238 in which the sharp ends of fasteners (not shown) can reside, so that they are protected by barrier wall 228 from contacting the contents of the crate.
In this way, boxes and crates can be erected having a greater strength combined with simplicity of assembly than ever before achieved. Boxes or crates assembled using the side and corner connectors disclosed herein may be further held together by traditional banding, packing tape, etc, or may be held together solely by the side connectors employed alone, the corner connectors employed alone, or any combination of side and corner connectors disclosed herein.
The principles, preferred embodiment and modes of operation of the present invention have been described in the foregoing specification. The invention is not to be construed as limited to the particular forms disclosed because these are regarded as merely illustrative, rather than restrictive. Moreover, variations and changes may be made by those skilled in the art without departing from the spirit of the invention as described by the following claims.
While the embodiments of the invention have been disclosed, certain modifications may be made by those skilled in the art to modify the invention without departing from the spirit of the invention.
Claims
1. A shipping container for transporting cargo, the shipping container comprising:
- a plurality of side panels;
- at least one of a top panel and a bottom panel;
- at least one corner connector assembly interconnecting two side panels of the plurality of side panels and the at least one of the top panel and the bottom panel, the at least one corner connector assembly including a pair of coupling members oriented in a predetermined relation to each other, each coupling member including: a first sidewall oriented so as to be parallel to a corresponding one of the two side panels being interconnected, a top sidewall oriented so as to be parallel to and support a corner section of the at least one of the top panel and bottom panel, a barrier wall connected to the top sidewall extending away from the top sidewall, and interior sidewall positioned between the first sidewall and the barrier wall, the interior sidewall being oriented so as to be parallel to the first sidewall, the first sidewall and the interior sidewall defining a channel that receives a corner section of the corresponding side panel; and
- a plurality of fasteners securing the at least one corner connector to the two side panels and the at least one of the top panel and the bottom panel so as to retain the two side panels and the at least one of the top panel and the bottom panel in a predetermined relation relative to each other, at least a first fastener of the plurality of fasteners being positioned such that a portion of the first fastener passing through the at least one corner connector extends into a space defined at least by the second sidewall and the interior sidewall,
- wherein at least the barrier wall is operable to shield the cargo from contact with the first fastener.
2. A shipping container for transporting cargo, the shipping container comprising:
- a plurality of side panels;
- at least one of a top panel and a bottom panel;
- at least one edge connector interconnecting a side panel of the plurality of side panels and the at least one of the top panel and the bottom panel, the at least one edge connector including: a first sidewall constructed so as to be parallel to the side panel, a second sidewall constructed so as to be parallel to and support an edge section of the at least one of the top panel and the bottom panel, a barrier wall connected to the second sidewall and extending away from the at least one of the top panel and the bottom panel, and a first interior sidewall positioned between the first sidewall and the barrier wall, the interior sidewall being constructed so as to be parallel to the first sidewall, the first sidewall and the interior sidewall defining a channel that receives an edge section of the side panel;
- at least one fastener securing the at least one edge connector to the side panel and the at least one of the top panel and the bottom panel so as to retain the side panel and the at least one of the top panel and the bottom panel in a predetermined relation, at least a first fastener of the at least one fastener being positioned such that a portion of the first fastener passing through the at least one edge connector extends into a space defined at least by the barrier wall and the interior sidewall,
- wherein at least the barrier wall is operable to shield the cargo from contact with the first fastener.
3. An edge connector for use in constructing a shipping container that includes a plurality of side panels, at least one of a top panel and a bottom panel, and a plurality of fasteners, the edge connector being operable to interconnect a side panel of the plurality of side panels and the at least one of the top panel and the bottom panel, the edge connector comprising:
- a first exterior side member;
- a second exterior side member oriented non-parallel to the first exterior side member and constructed so as to support an edge section of the at least one of the top panel and the bottom panel, the second exterior side member defining a first surface and a second surface, the first surface of the second exterior side member being operable to contact the edge section of the at least one of the top panel and the bottom panel when the edge section of the at least one of the top panel and the bottom panel is placed upon the second exterior side member;
- a third exterior side member connected to the second exterior side member and extending in a direction generally opposite the first surface of the second exterior side member; and
- an interior side member positioned between the first exterior side member and the third exterior side member, the interior side member being substantially parallel to the first exterior side member, the first exterior side member and the interior side member defining a channel that is operable to receive an edge section of the side panel;
- wherein at least the third exterior side member and the interior side member define a space operable to receive and contain an end portion of a fastener passing through at least one of the interior side member and the second exterior side member such that the end portion of the fastener does not pass through the third exterior side member.
Type: Application
Filed: Sep 29, 2008
Publication Date: Jan 6, 2011
Inventor: James Michael Wood (Jacksonville, FL)
Application Number: 12/733,932
International Classification: B65D 88/00 (20060101);