HIGH DENSITY PALLET SYSTEM
A pallet system for shipping a number of spools includes a pad which supports and retains a first layer of spools. A separator is disposed atop the first layer of spools and a second layer of spools is disposed atop the separator. Subsequent layers of spools and separators may be included in a stacked relationship, and a cap member is disposed atop the topmost layer of spools. The pad, cap, and separators form a stacked shipping unit and may include locking features and provisions for retaining straps.
This application claims priority of U.S. Provisional Patent Application 61/473,374 filed Apr. 8, 2011, entitled “High Density Pallet System”, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTIONThis invention relates, generally, to packing systems. More specifically, the invention relates to pallet systems. In particular, the invention relates to pallet systems which allow for the high-density packing and shipping of cylindrical members such as spools of yarn, thread, or other filamentary material.
BACKGROUND OF THE INVENTIONFilamentary material such as yarn, thread, and the like is frequently wound onto spools for shipping from a manufacturing facility to a use facility. These spools generally are configured to fit directly into end use manufacturing equipment. Typically, large numbers of wound spools are shipped to distribution or end use manufacturing facilities; hence, there is a need for a packing system which can securely retain such spools for shipping. In addition to being simple to use, such shipping systems should be light in weight, low in cost, and allow for the high-density packing of wound spools.
Goods are increasingly being shipped via containerized freight systems which utilize standard-dimension freight containers. Hence, any cargo shipping system should be configured to be compatible with standard freight containers such that wasted space is minimized or eliminated, and maximum packing density achieved. Spools used for filamentary materials typically include a core portion about which the filamentary material is wound, and in many cases, portions of this core project from the spool so as to allow mounting of the core onto use or processing equipment.
As will be explained in detail hereinbelow, the present invention comprises a palletized system which provides for the high-density packing of spool-wound material. The system of the present invention is configured to provide palletized stacks of spooled material which may be readily handled by forklifts, cranes, and other such processing equipment, and which are dimensioned so as to allow for high-density packing in standardized shipping containers. These and other advantages of the present invention will be apparent from the drawings, discussion, and description which follow.
BRIEF DESCRIPTION OF THE INVENTIONDisclosed is a pallet system for retaining a plurality of spools of the type comprising a core having a filamentary material wound thereabout. The system includes a pad or pallet having a first face configured to rest on a support surface and a second face having a plurality of spool-engaging features defined thereupon. The spool-engaging features are each configured and operable to engage a spool so that the pad is capable of supporting a layer of spools on its second face in a predetermined pattern. The system further includes at least one separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon in the predetermined pattern. The system further includes a cap having a first face with a plurality of spool-engaging features defined thereupon in the predetermined pattern. The components of the system are configured and operable so that in the use of the system, the second surface of the pad receives and supports a first layer of spools thereupon in the predetermined pattern, and the spool-retaining features of one of the separators engages the first layer of spools. Further in the use of the system, a second layer of spools is supported on the second face of the separator. In a typical application, a further number of separators and corresponding layers of spools are added to the pallet system, and the cap member is then disposed atop the topmost layer of spools so that its spool-engaging features engage those spools so as to form a completed shipping unit.
In particular embodiments, the spool-engaging features may comprise conical protrusions which engage the core portions of the spool. In other instances, the spool-engaging features may comprise recesses which receive projecting portions of the cores of the spools. In further embodiments, the components of the pallet system may be configured to define one or more grooves which operate to receive a strapping member. The cap and/or pad members may be configured to define further features such as forklift access channels, stabilizing legs, forklift guides, lift pads for robotic devices, locking features, and the like.
The components of the pallet system may be fabricated from a polymeric material such as high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene, -styrene, polypropylene, polyethylene, and combinations thereof. In some instances the polymer may include a reinforcing material therein. The pallet components may be formed by thermoforming. In some instances, the components of the system may be configured so that the plurality of spools may be disposed in a staggered matrix. In some embodiments, the first face of the pad component is configured so as to be engageable with a second face of the cap so that completed shipping units may be readily stacked atop one another.
Further disclosed is a method for packing a series of spools of material through the use of the pallet system of the present invention.
FIGS. 5C,5D and 5E are enlarged views of portions of the cross-sectional view of
The palletized system of the present invention includes components which allow for the high-density stacking of a plurality of layers of wound spools. As such, the system includes a pad member, a cap member, and a plurality of separator members configured to be disposed therebetween and retain a number of layers of wound spools. The system of the present invention may be configured in a variety of implementations, and some illustrative examples thereof are presented herein.
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In view of the foregoing, it will be appreciated that the system of the present invention allows for the secure, high density, reliable stacking of spooled material. Various stacking configurations may be achieved through the use of various combinations of the aforedescribed pads, caps, and separators of the present invention so as to provide maximum filling of shipping containers of differing sizes. As will be seen, the pads and caps may be further configured so that their outer faces can positively engage one another so as to allow several stacked units each comprised of a pad, a cap, separators, and spools disposed therebetween, to be placed atop one another. By appropriately selecting the number of layers and units, a stacked assembly may be prepared so as to fit standard cargo containers. As will be understood in the art, these stacks may be banded together by strapping material utilizing the notches as previously discussed.
As mentioned above, the system of the present invention may be configured in a variety of embodiments, and another such embodiment is illustrated in
The pad member 16 is further configured to include features including lid locks 50, pallet feet 52, and strapping detents as shown for example at reference numeral 54. The pallet may also include fork leveling pads, as shown at reference numeral 58, and these pads can aid in guiding a forklift and in that regard work together with associated fork openings 22 as defined by the pallet feet 52. The pallet may further include robotic vacuum lift pads as shown for example at reference numeral 56, and these pads provide a smooth surface which is engageable by a robotic lifting device.
Referring now to
In general, the pad, cap, and separator members are fabricated from polymeric materials, since such materials are generally low in cost, high in strength, lightweight, and dimensionally stable. Some specific polymeric materials utilized to fabricate these members include high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene-styrene (ABS), polypropylene, other polyethylenes, and various combinations of the foregoing materials. As is known in the art, the polymers may include reinforcing materials such as fibrous materials therein as well as fillers, coloring agents, and the like. In specific instances, the components are fabricated from thermoplastic polymers utilizing various molding or shaping processes. In one specific instance, the components are fabricated by thermoforming polymeric stock. In other instances, they may be fabricated by injection molding or other such processes. In yet other instances, the components may be manufactured from thermosetting polymeric materials or curable resin materials. All of such implementations are within the scope of the present invention.
The foregoing describes some specific implementations of the present invention. Other implementations, modifications, and variations thereof will be apparent to those of skill in the art. The foregoing drawings, discussion, description, and examples are illustrative of specific embodiments of the present invention but are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.
Claims
1. A pallet system for retaining a plurality of spools, each spool including a core having a filamentary material wound thereabout, said system comprising:
- a pad having a first face configured to rest upon a support surface and a second face having a plurality of spool-engaging features defined thereupon, each spool-engaging feature being configured and operable to engage a spool so that said pad is capable of supporting a layer of said spools on said second face in a predetermined pattern;
- at least one separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-engaging features being disposed in said predetermined pattern;
- a cap having a first face having a plurality of spool-engaging features defined upon said first face thereof, said spool-engaging features being disposed and operable so as to engage said spools in said predetermined pattern;
- wherein said pad, said at least one separator, and said cap are configured and operable so that in the use of said system, said second surface of said pad can receive and support a first layer of spools thereupon in said predetermined pattern, and the spool-engaging features of a first one of said at least one separator engage said first layer of spools, and wherein a second layer of spools may be supported on the second face of said one of said at least one separators; and wherein said spool-engaging features of said cap can engage a layer of spools supported on either the second face of said first one of said at least one separators, or on a second face of another one of said at least one separators.
2. The pallet system of claim 1, wherein the spool-engaging features of at least one of said pad, said at least one separator, and said cap are each configured to project into the core of a spool.
3. The pallet system of claim 2, wherein said spool-engaging features which are each configured to project into the core of a spool comprise conical features.
4. The pallet system of claim 1, wherein the spool-engaging features of at least one of: said pad, said at least one separator, and said cap are each configured so as to engage a spool and permit a portion of the length of the core of said spool to project thereinto.
5. The pallet system of claim 1, wherein said spool-engaging features which are each configured to permit a portion of the length of the core of said spool to project thereinto comprise openings defined in a respective one of said pad, said at least one separator, and said cap.
6. The system of claim 1, wherein said pad, said at least one separator, and said cap are formed from a polymeric material.
7. The system of claim 6, wherein said polymeric material is a thermoformed polymeric material.
8. The system of claim 6, wherein said polymeric material is selected from the group consisting of high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene-styrene, polypropylene, polyethylene, and combinations thereof.
9. The system of claim 6, wherein said polymeric material includes a reinforcing agent therein.
10. The system of claim 1, wherein the first face of said pad is configured to be engageable by a lift fork.
11. The system of claim 1, wherein at least one of said pad, said at least one separator, and said cap include a notch therein configured to engage a binding strap.
12. The system of claim 1, wherein said first face of said pad is further configured so as to be engageable with a second face of said cap which second face is opposite the first face thereof.
13. The system of claim 1, wherein at least one of said pad, said cap, and said separator is configured to be gripped by a robotic lifter.
14. The system of claim 1, wherein said spool-engaging features define a staggered matrix.
15. A method for packing spools, each spool including a core having a filamentary material wound thereabout, said method comprising:
- (a) providing a pad having a first face configured to rest upon a support surface and a second face having a plurality of spool-engaging features defined thereupon, each spool-engaging feature being configured and operable to engage a spool so that said pad is capable of supporting a layer of said spools on said second face, in a predetermined pattern;
- (b) disposing a first plurality of spools on said pad so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of said pad;
- (c) providing a first separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-engaging features being disposed in said predetermined pattern;
- (d) disposing said first separator so that said spool-engaging features of said first face each engage a respective one of said spools of said first plurality of spools;
- (e) disposing a second plurality of spools on said second face of said first separator so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of the second face of said first separator;
- (f) providing a second separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-retaining features being disposed in said predetermined pattern;
- (g) disposing said second separator so that said spool-engaging features of said first face each engage a respective one of said spools of said second plurality of spools;
- (h) disposing a third plurality of spools on said second face of said second separator so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of the second face of said second separator;
- (i) optionally, repeating steps (f)-(h) one or more times utilizing at least a third separator and at least a fourth plurality of spools;
- (j) providing a cap having a first face having a plurality of spool-engaging features defined upon said first face thereof, said spool-engaging features being disposed in said predetermined pattern; and
- (k) disposing said cap so that said spool-engaging features of said first face each engage: a respective one of said spools of said third plurality of spools, or a respective one of said spools of said at least a fourth plurality of spools.
Type: Application
Filed: Apr 5, 2012
Publication Date: Oct 11, 2012
Inventors: Richard Edmond Jositas (Oakland, MI), Ryan Victory (Royal Oak, MI)
Application Number: 13/440,151
International Classification: B65D 19/44 (20060101); B65B 35/50 (20060101);