SYSTEMS AND ASSEMBLIES FOR STORING AND TRANSPORTING PRODUCT ROLLS

Description

FIELD

The present disclosure relates generally to transportation or storage packaging, and more specifically to assemblies for transportation or storage of product rolls and a system of transporting the assemblies containing the product rolls.

BACKGROUND

Conventionally, various containers are used to protect products during storage, handling, and transportation of said products, such as material packaged in the form of rolls (e.g. rolls of fabric, etc.). Typically, product rolls are stored and transported in containers that are less durable, cannot be reused (e.g. for another storage or transportation cycle), and cannot easily or efficiently be broken down in multiple parts for return (e.g. to be used for another storage or transportation cycle).

SUMMARY OF THE INVENTION

Aspects of the present invention are directed to transportation or storage packaging of product rolls as well as systems of transportation thereof.

In accordance with one aspect of the present invention, a stackable case assembly includes a roll support, a case bottom, and a case top. The roll support has a shaft extending between an end portion and an opposite end portion. The roll support includes at least one spacer coupled to at least one of the end portion or the opposite end portion. The case bottom is disposed between and connected to the end portion and the opposite end portion. The case bottom also includes a first peripheral edge configured to mate with a second peripheral edge of the case top. In a transportation configuration, the case top is releasably joined with the case bottom using one or more latches, and the case bottom and case top together define a cavity configured to receive at least the roll support. In a storage configuration, one of the case top or case bottom is configured to nest within the other.

In accordance with another aspect of the present invention, a system for storing or transporting at least one roll of product includes a pallet, a plurality of stackable case assemblies, and one or more cleats. The plurality of stackable case assemblies are stacked one on top of the other and on the pallet. At least one of the plurality of stackable case assemblies includes a roll support, a case bottom, and a case top. The roll support includes a shaft extending between an end portion and an opposite end portion. The roll support has at least one spacer coupled to at least one of the end portion or the opposite end portion. The case bottom is disposed between and connected to the end portion and the opposite end portion. The case bottom includes a first peripheral edge configured to mate with a second peripheral edge of the first peripheral edge. In a transportation configuration, the case top is releasably joined with the case bottom using one or more latches, and the case bottom and case top together define a cavity configured to receive at least the roll support. In a storage configuration, one of the case top or case bottom is configured to nest within the other. The one or more cleats are disposed on the pallet and configured to secure the plural stackable case assemblies on the pallet.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The invention is best understood from the following detailed description when read in connection with the accompanying drawings, with like elements having the same reference numerals. When a plurality of similar elements are present, a single reference numeral may be assigned to the plurality of similar elements with a small letter designation referring to specific elements. When referring to the elements collectively or to a non-specific one or more of the elements, the small letter designation may be dropped. This emphasizes that according to common practice, the various features of the drawings are not drawn to scale unless otherwise indicated. On the contrary, the dimensions of the various features may be expanded or reduced for clarity. Included in the drawings are the following figures:

FIG. 1A depicts an isometric view of a stackable case assembly according to an exemplary embodiment of the invention;

FIG. 1B depicts a front view of the stackable case assembly of FIG. 1A;

FIG. 1C depicts a top view of the stackable case assembly of FIG. 1A;

FIG. 1D depicts a bottom view of the stackable case assembly of FIG. 1A;

FIG. 1E depicts a side view of the stackable case assembly of FIG. 1A;

FIG. 1F depicts another isometric view of the stackable case assembly of FIG. 1A, showing an embodiment of a case top according to an aspect of the invention;

FIG. 2 depicts another isometric view of the stackable case assembly of FIG. 1A, showing another embodiment of a case top according to an aspect of the invention;

FIG. 3 depicts an exploded view of a stackable case assembly according to an exemplary embodiment of the invention;

FIG. 4A depicts a top view of a stackable case assembly according to an exemplary embodiment of the invention;

FIG. 4B depicts a cross-section view of the stackable case assembly of FIG. 4A, taken along line 4B-4B;

FIG. 4C depicts a magnified view of a portion of the stackable case assembly of FIG. 4A;

FIG. 5A depicts a front view of a stackable case assembly according to an exemplary embodiment of the invention;

FIG. 5B depicts a cross-section view of the stackable case assembly of FIG. 5A, taken along line 5B-5B;

FIG. 6 depicts a partial exploded view of a stackable case assembly according to an exemplary embodiment of the invention;

FIG. 7 depicts a section view of a portion of a stackable case assembly according to an exemplary embodiment of the invention;

FIGS. 8A-8B depict a system for storing or transporting at least one roll of product according to an exemplary embodiment of the invention; and

FIG. 9 depicts a pallet of the system of FIGS. 8A-8B according to an exemplary embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the invention are described herein with reference to transporting rolls of fabric. However, it will be understood by one of ordinary skill in the art that the example devices described herein may be used to transport a variety of products and materials (e.g., plastics and other sheet-type materials, fibers, threads, etc.) capable of being rolled and unrolled (e.g. about a rod or support member), and are not limited to any product roll disclosed herein. Other products suitable for transportation or storage with the disclosed apparatuses and assemblies will be known to one of ordinary skill in the art from the description herein.

Additionally, various forms and embodiments of the invention are illustrated in the figures. It will be appreciated that the combination and arrangement of some or all features of any of the embodiments with other embodiments is specifically contemplated herein. Accordingly, this detailed disclosure expressly includes the specific embodiments illustrated herein, combinations and sub-combinations of features of the illustrated embodiments, and variations of the illustrated embodiments.

With reference to the drawings, FIGS. 1A-1F and 3 show an exemplary stackable case assembly 100. In an exemplary embodiment, the stackable case assembly is configured to store or transport at least one roll of product 200. In general, stackable case assembly 100 includes a roll support 110, a case bottom 120, and a case top 130. Container or case assembly 100 is configured to be stackable, such that an identical case assembly 100 may be stacked above another case assembly 100. Specifically, the case assembly 100 is configured to be stackable without impeding the security of the roll of product 200 within an interior space of the case assembly 100, or security of a plurality of case assemblies 100 within in a transportation or storage configuration. Individual components of stackable case assemblies 100 will now be described in detail below.

As shown in FIGS. 1A-1E, the case assembly 100 can be formed from one or more structures which together define a cavity or interior (space) 170 (FIG. 5B), with at least the roll support 110 and roll of product 200 being positioned within the interior space in the case assembly 100. Specifically, the one or more structures include a case top 130 and case bottom 120, as best shown in FIG. 3, for example. As seen in FIG. 3, the at least one roll of product 200 (e.g. roll of fabric) is provided or positioned within this cavity or space 170 of the case assembly 100, thereby providing protection for at least these components (e.g. during storage, transportation, or combination thereof). To achieve this, in one non-limiting example, as shown in FIG. 3, the case bottom 120 includes a first peripheral edge 122 configured to mate with a second peripheral edge 132 of the case top 130. Additionally or optionally, the first peripheral edge 122 and second peripheral edge 132 may have a generally square or rectangular geometry. Although the case top 130 and case bottom 120 are illustrated as separate components, one of ordinary skill in the art would understand from the description herein that the case top 130 and the case bottom 120 may be integrally formed as a single body of unitary construction.

In an exemplary embodiment, the case top 130 and the case bottom 120 are each made of more durable or rigid material (e.g. relative to or as compared to the products configured to be contained therein, such as fabric, threads, etc.). The more rigid material 516 is intended to provide support and/or a mounting structure for the components of the case assembly 100 (e.g. roll support 110, roll of product 200, etc.). In one non-limiting example, the case top 130 and the case bottom 120 are made of different materials, but it would be understood from the description herein that in the alternative, the case top 130 and the case bottom 120 may comprise the same material. Further, as best illustrated in FIG. 6, the case top 130 defines a base 136 and a plurality of side walls 138 extending upwardly (when in a first or open position as illustrated in FIG. 6) or downwardly (when in a second or closed position as illustrated in FIG. 3) from the first base 136. Additionally or optionally, the case bottom 120 defines a similar base 126 (FIG. 1D) and plurality of side walls 128 (FIG. 6) extending upwardly from the base 126. The plurality of side walls 138 include a support surface 139 positioned to elevate at least a shaft 112 (discussed below) relative to the base 136. In an exemplary storage configuration (e.g. FIG. 6), the support surface 139 of the case top 130 or case bottom 120 is configured to contact at least an end portion and an opposite end portion of the shaft 112 of the roll support 110 to limit or reduce movement of at least the shaft 112. In an exemplary transportation configuration (e.g. FIG. 4B), the support surface 139 of the case top 130 or case bottom 120 is configured to contact at least an end portion of the shaft 112 and an opposite end portion of the shaft 112 of the roll support 110 to limit or reduce movement of at least the shaft 112 (and therefore movement of all or portion of the roll of product 200 if wound about the shaft 112).

The outer and inner surfaces of each of the case top 130 and the case bottom 120 are customizable in size, texture, color, geometry or other characteristic to satisfy one or more functional or aesthetic parameters, as desired or as dictated by the roll of product 200 to be stored and/or transported. In one non-limiting example, an outer surface of 124 of the case bottom 120 and/or an outer surface 134 of the case top 130 define a plurality of protrusions or grooves for facilitating the stackable configuration of case assemblies 100 (e.g. an identical case assembly 100 may be stacked above another case assembly 100). Namely, the outer surface 134 of the case top 130 of a first, case assembly 100 define the plurality of protrusions or grooves as having a size and shape that correspond to the size and shape of the corresponding plurality of protrusions or grooves of the outer surface 124 of the case bottom 120 of a second, identical case assembly, such that each protrusion of the outer surface 134 or outer surface 124 is received by and/or mated to a respective groove of the other of the outer surface 134 or outer surface 124. Additionally or optionally, in a transportation configuration of the case assembly 100 (e.g. in which the case assembly 100 and contents therein are configured to be moved from one location to another, as illustrated for example in FIGS. 1A-1F), the case bottom 120 and the case top 130 may be releasably joined together using at least one latch 300 moveable between unlatched and latched states. When the at least one latch 300 is in the latched state, the case bottom 120 and the case top 130 are secured together. The type and number (e.g. six) of latches 400 illustrated in FIGS. 1A-1F, for example, are not intended to be limiting, and one skilled in the art would understand from the description herein that various types and numbers of latches 400 are contemplated without departing from the spirit of the invention.

Still further, in a storage configuration (FIGS. 6-7), one of the case top or case bottom is configured to nest within the other. In an exemplary embodiment, the case top 130 is configured to partially nest within the case bottom 120. The storage configuration includes, but is not limited to, a state of the case assembly 100 before a roll of product 200 is placed within the cavity 170 (FIG. 5B) formed by the case bottom 120 and case top 130 and after a roll of product 200 is transported/delivered within the case bottom 120 and case top 130 (e.g. after a transportation cycle). The storage configuration also includes the case assembly 100 optionally containing at least one roll of product 200 before or after the transportation configuration (e.g. stored before delivery/transportation at a location or stored after delivery/transportation in another location).

Turning now to FIGS. 3, 4A-4C, and 5A-5B, case assembly 100 includes the roll support 110. In an exemplary embodiment, the roll support 110 includes the shaft 112 extending between the end portion and the opposite end portion. Additionally or optionally, the roll support 110 includes at least one spacer 116 coupled to at least one of the end portion or the opposite end portion. In an exemplary embodiment, when the shaft 112 is disposed in the interior space defined by the case bottom 120 and case top 130, the end portion and the opposite end portion of the shaft 112 is configured to be supported and/or secured by the support surface 139 of the case bottom 120 (as best shown in FIG. 4B). Still further, all or a portion of the roll of product 200 is configured to be wound onto the roll support 110. In a non-limiting example, the roll support 110 includes a core 114 configured to be would around the shaft 112 and the roll of product 200 is configured to be would onto the core 114 and the shaft 112, then secured via the spacer 116 coupled to the end portion and opposite end portion of the shaft 112. Alternatively, the roll of product 200 includes the core 114 around which the roll of product 200 is wound, and the roll of product 200 is wound onto the shaft 112.

Turning now to FIGS. 1F, 2, 4A-4C, and 5A-5B, when the first peripheral edge 122 is mated to the second peripheral edge 132, the first peripheral edge 122 and the second peripheral edge 132 form a plurality of openings 140 (FIG. 1F) configured to receive one of the end portion and the opposite end portion of the shaft 112. In this way, at least a portion of the roll support 110 is visually perceptible via the plurality of openings 140. Alternatively, as shown in FIG. 2, when the first peripheral edge 122 is mated to the second peripheral edge 132, the first peripheral edge 122 is nested within the second peripheral edge, such that at least the shaft 112 disposed within is not visually perceptible. In either configuration, the case bottom 120 is configured to partially nest within the case top 130, such that an inner surface of the case top 130 is configured to mate with an outer surface of the case bottom 120, thereby forming a fluid tight connection between the case top 130 and the case bottom 120.

Additionally or optionally, as best shown in FIGS. 4A-4C, the at least one spacer 116 is coupled to (i.e., directly or indirectly joined with) the respective end portion of the shaft 112 and the opposite end portion of the shaft 112, the at least one spacer 116 is at least partially received within the plurality of openings 140, thereby limiting or reducing movement of at least the shaft 112. In this way, movement of the roll of product 200 within the interior space or cavity 170 of the case assembly 100 is mitigated or prevented, thereby reducing or limiting damage through forceful contact with various surfaces (e.g. interior surface of case top 130 and case bottom 120). In a non-limiting example, this is achieved, at least in part, because of an interface between a surface of the at least one spacer 116 and an interior surface of one or more of the case bottom 120 and case top 130 (see FIG. 4C). Additionally or optionally, the at least one spacer 116 is detachable from the at shaft 112, such as in a transportation or storage configuration in which the at least one roll of product 200 is absent from within the case assembly 100. One skilled in the art would understand from the description herein that the at least one spacer 116 has a size and that would correspond to the shape and size of at least one or more of the shaft 112, the case top 130, case bottom 120.

In an exemplary embodiment of the invention, as best shown in FIG. 6, an identical case assembly may be stacked on top of the stackable case assembly 100. In the storage configuration, transportation configuration, or a combination thereof, a case bottom 120a of the identical case assembly is configured to at least partially nest within a case top 130b of the stackable case assembly 100. Additionally or optionally, the case top 130b of the stackable case assembly 100 is configured to at least partially nest within a case bottom 120b of the stackable case assembly 100. Additionally or optionally, as show in FIG. 7, the support surface 139 of the plurality of side walls 138 of the case top 130b is configured to elevate the case bottom 120a of the identical case assembly relative to the base 136 of the case top 130b. Additionally or optionally, the case bottom 120b of the stackable case assembly defines a base 126 and a plurality of side walls 128 extending upwardly from the base 126, and the plurality of second side walls 128 has a support surface 150 positioned to elevate the case top 130b of the stackable case assembly relative to the base 126. In this way, the outer surface of the case top 130b is engageably coupled with an inner surface of the case bottom 120b of the case assembly (FIG. 7).

Turning now to FIGS. 8A-8B and 9, a system 1000 for storing or transporting at least one roll of product 200 is provided. In general, the system 1000 includes a pallet 300 and a plurality of stackable case assemblies 100, such as the case assemblies discussed above, configured to be stacked one on top of the other and on the pallet 300. Additional details of the system 100 is discussed below.

One or more cleats 310 are disposed on the pallet 300 and configured to secure the plural stackable case assemblies 100 on the pallet 300. As shown in FIG. 9, pallet 300 generally has a square or rectangular geometry and defines an outer perimeter. One or more cleats 310 are disposed along the outer perimeter and may be uniformly or non-uniformly spaced apart from each other based on the shape and size of at least the outer surface 124 of the case bottom 120 of the case assembly 100. Further, a central cleat 310 may be disposed at a center of the pallet 300 for added stability and/or security of the plural case assemblies 100 stacked on the pallet 300.

In an exemplary embodiment, the case bottom 120 of the bottom-most case assemblies 100 of the plural stackable case assemblies 100 is configured to stand on the pallet 300. In this configuration, a bottom portion of the outer surface 124 of the case bottom 120 of the bottom-most case assemblies (e.g. first case assembly 1100, second case assembly 1200, third case assembly 1300, etc.) is engageably coupled to the pallet 300 and the one or more cleats 310, thereby limiting or reducing movement of the plural stackable case assemblies 100 relative to the pallet 300. Additionally or optionally, in the transportation configuration or the storage configuration, the outer surface 134 of the case top 130 of the stackable case assembly is engageably coupled with the bottom portion of the outer surface 124 of the case bottom 120 of the identical case assembly 100. When all or a portion of the at least one roll of product 200 is wound onto the roll support 110, the first case assembly 1100 is configured to stand on the pallet 300, a case top 130 of the first case assembly 1100 is configured to at least partially nest within a case bottom 120 of the first case assembly 1100, and a case bottom 120 of a second case assembly 1200 is configured to at least partially nest within the case top 130 of the first case assembly 1100. In an exemplary embodiment, as described with respect to FIGS. 6 and 7 above, the case top 130 of the first case assembly 1100 defines the support surface 139 positioned to elevate the shaft 112 relative to the pallet 300. Additionally or optionally, the support surface 139 is further configured to elevate the case bottom 120 of the second case assembly 1200 relative to the pallet 300.

In a further exemplary embodiment, when the first peripheral edge 122 is mated to the second peripheral edge 132, the first peripheral edge 122 and the second peripheral edge 132 form the plurality of openings 140 configured to receive one of the end portion and the opposite end portion of the shaft 112. The shaft 112 includes a hollow cylinder defining a channel 160 (FIG. 5B) that is concentric with the plurality of openings 140. In this way, in the transportation configuration, an external member (not shown) may be configured to spear through the plurality of openings 140 and the channel 160 of the roll support 110 while the case top 130 is joined with the case bottom 120 using the one or more latches 400.

Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.