Patent application title:

PANEL FRAME OPTIMIZED FOR COMPACT STACKING DURING SHIPMENT

Publication number:

US20260062917A1

Publication date:
Application number:

19/317,277

Filed date:

2025-09-03

Smart Summary: A panel frame is designed to stack compactly for shipping. It has two main beams that run the length of the frame. Attached to these beams are two smaller beams with flat ends. The smaller beams are deeper near the flat ends and connect to the main beams. The flat ends are long enough to match the width of the main beams but are not as deep as the smaller beams. 🚀 TL;DR

Abstract:

A panel frame optimized for compact stacking during shipment may include a first and second primary beams that define a length. First and second secondary beams may include flats at their ends, the flats attached to the primary beams along the primary beams' lengths. The secondary beams may define a secondary beam maximum depth adjacent to the flats, opposite the attachment to the primary beams, and perpendicular to the flats. The primary beams may define a beam maximum width parallel to the secondary beam and define a primary beam maximum depth at the attachment to the secondary beams and perpendicular to the maximum width. The flats may each define a flat length parallel to and at least as long as the beam maximum width, and may define a flat depth parallel to the primary beam maximum depth, the flat depth being less than the secondary beam maximum depth.

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Classification:

E04C2/38 »  CPC main

Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Application Ser. No. 63/691,023, filed on Sep. 5, 2024, which is incorporated herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a panel frame and, more particularly, to a panel frame the configuration of which is optimized for compact stacking with like panel frames for shipment.

Panel frames may serve several functions. As nonlimiting examples, they may be used for construction of panel barriers for manufacturing sites, for fencing, and for animal kennel walls.

It is desirable to provide a panel frame design that may be manufactured at a first location better suited for economical manufacturing, and assembled there as much as possible, to take advantage of economies of scale. However, such panel frames then need to be easily and compactly shipped to a second location, such as a point of sale. Shipping costs may be reduced if such panel frames, when stacked together, are as compact as possible.

In such a context, and recognizing the need to minimize shipping costs by maximizing compactness of stacking for shipping, it would be desirable for a panel frame to have optimized strength yet be configured such that multiple such panel frames may be compactly stacked together. These two goals often compete against each other.

In view of the foregoing, the present invention relates to an improvement upon the known systems and methods of panel frames and provides distinct advantages over the conventional systems and methods.

SUMMARY OF THE INVENTION

Embodiments of panel frames optimized for compact stacking during shipment are provided.

It has been found that the present invention provides cost savings by allowing, for example from some embodiments, 20% more units of panel frames to be packed into the interior space of a container yielding a 4% net landed cost savings.

Aspects and advantages of the invention are set forth below in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In accordance with certain aspects of certain embodiments of the present technology, a panel frame optimized for compact stacking during shipment may include first and second primary beams residing parallel to each other, residing in a plane, with each defining a beam maximum width perpendicular to the beam and parallel to the plane. A plurality of secondary beams may also be included. Each secondary beam may define a beam maximum depth perpendicular to the plane and have a flat on both ends. Each flat may define a flat depth that is less than the beam maximum depth and define a flat length that is greater than the beam maximum width. Each flat may be attached at its end either to a primary beam along its length or to a secondary beam along its length. Additionally and/or alternatively, in various embodiments one or more of the following features may also be included:

    • a. all secondary beams may be identical;
    • b. all secondary beams may reside perpendicular to the primary beams;
    • c. at least one of the secondary beams may be perpendicular to the primary beams and at least one of the secondary beams may be parallel to the primary beams;
    • d. the first and second primary beams may define the beam maximum depth;
    • e. each of the secondary beams may define a width equal to the beam maximum width; and/or
    • f. the primary beams and the secondary beams may have a circular cross-section.

In accordance with other embodiments of the present invention, panel frames optimized for compact stacking during shipment may include a first panel frame that includes a first primary beam, the first primary beam defining a first length, and a second panel frame that includes a second primary beam, the second primary beam defining a second length. A first secondary beam may be attached to the first primary beam along the first length. The first second beam may include a flat proximate to the attachment of first secondary beam to the first primary beam. The flat may define a flat depth perpendicular to both the first primary beam and the first secondary beam and may define a maximum depth adjacent to the flat, opposite the attachment to the first primary beam and parallel to the flat depth, with the maximum depth being greater than the flat depth. A second secondary beam may also be included that is attached to the second primary beam along the second length. The second primary beam may reside parallel to the first primary beam and be in contact with the flat. Additionally and/or alternatively, in various embodiments one or more of the following features may also be included:

    • a. the contact is direct contact;
    • b. the second secondary beam is identical to the first secondary beam;
    • c. the first and second primary beams and the first and second secondary beams each define a circular cross-section;
    • d. the first and second secondary beams are both perpendicular to the first primary beam;
    • e. the maximum depth is greater than twice the flat depth; and/or
    • f. further including a third secondary beam, the third secondary beam being attached to the first secondary beam.

In accordance with yet still other embodiments of the present invention, a panel frame optimized for compact stacking during shipment may include a first primary beam that defines a first length and a second primary beam that defines a second length. It may also include a first secondary beam attached to the first primary beam along the first length and attached to the second primary beam 22 along the second length. The first secondary beam may include a first flat proximate to the attachment of first secondary beam to the first primary beam, the first flat defining a first maximum depth adjacent to the first flat, opposite the attachment to the first primary beam, and perpendicular to the first flat. The first secondary beam may also include a second flat proximate to the attachment of the first secondary beam to the second primary beam that defines a second maximum depth adjacent to the second flat, opposite the attachment to the second primary beam, and perpendicular to the second flat. The first primary beam may define a first maximum width parallel to the first secondary beam at the attachment to the first secondary beam and define a third maximum depth at the attachment to the first secondary beam and perpendicular to the first maximum width. The second primary beam may define a second maximum width parallel to the first secondary beam at the attachment to the first secondary beam and defining a fourth maximum depth at the attachment to the first secondary beam perpendicular to the second maximum width. The first flat may define a first flat length parallel to and at least as long as the first maximum width, and may define a first flat depth parallel to the third maximum depth, the first flat depth being less than the first maximum depth. The second flat may define a second flat length parallel to and at least as long as the second maximum width, and may define a second flat depth parallel to the fourth maximum depth, the second flat depth being less than the second maximum depth. Additionally and/or alternatively, in various embodiments one or more of the following features may also be included:

    • a. the first and second primary beams are identical;
    • b. the first maximum depth equals the first maximum width;
    • c. the first maximum depth, the second maximum depth, and the first maximum width are equal;
    • d. further including a second secondary beam, the second secondary beam identical to the first secondary beam and attached to the first primary beam and to the first secondary beam; and/or
    • e. the maximum depth is greater than twice the flat depth.

The foregoing description sets forth broadly certain features of the present invention so that the detailed description hereinbelow may be better understood, and so that the present contributions to the art from this invention may be better appreciated. Additional features of the invention will be described hereinbelow.

Modifications and variations to the specifically illustrated and/or discussed features and elements hereof may be practiced in various embodiments and uses of the invention without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like. Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matter may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly shown in the figures or stated in the detailed description of such figures). Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.

The purpose of the Abstract hereinabove is to enable the United States Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The Abstract is not provided for interpreting the scope of the claims herein, nor to define the invention or the application, nor to be limiting in any way as to the scope of the invention.

BRIEF DESCRIPTION OF DRAWINGS

The details of the present invention, as to both its structure and its operation, can be understood with reference to the accompanying drawings, in which:

FIG. 1A is a broken view of a detail of the prior art;

FIG. 1B is a broken view of a detail of the prior art;

FIG. 2A is a broken view of a detail of the present invention;

FIG. 2B is a broken view of a detail of the present invention;

FIG. 3 is an enlarged side elevation view of a detail of the present invention;

FIG. 4 is a simplified end view of a secondary beam according to an embodiment of the present invention;

FIG. 5A is a top plan view of a panel frame according to an embodiment of the present invention;

FIG. 5B is a top plan view of a panel frame according to an embodiment of the present invention;

FIG. 6 is a side elevation view of a panel frame according to an embodiment of the present invention;

FIG. 7 is a side elevation view of a panel frame according to an embodiment of the present invention;

FIG. 8 is a side elevation view of two stacked panel frames according to an embodiment of the present invention;

FIG. 9 is a side elevation view of two stacked panel frames according to an embodiment of the present invention;

FIG. 10A is a top plan partial view of three stacked panel frames according to an embodiment of the present invention;

FIG. 10B is a top plan partial view of three stacked panel frames according to an embodiment of the present invention;

FIG. 11 is a perspective view illustrating use of an embodiment of the present invention;

and

FIG. 12 is a perspective view illustrating use of an embodiment of the present invention.

It should be noted that the drawings discussed above and below are not to scale in all instances but may have exaggerated dimensions in some respect to illustrate the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Certain preferred embodiments and examples are disclosed herein. However, the inventive subject matter extends beyond the examples in the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims below is not limited by any of the particular embodiments described herein. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Additionally, the structures, systems, and/or devices described herein may be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments may be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as may also be taught or suggested herein.

It is to be understood that the phraseology used herein is for the purpose of description and should not be regarded as limiting. The use of formatives of the words “include,” “comprise,” and “have” is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items.

Unless specified or limited otherwise, the terms “attached,” “connected,” and “carried by” are used broadly and encompass direct and indirect mountings, connections, supports, or couplings. Further, such phraseology is not limited to physical or mechanical connections or couplings.

As used herein, the terms “above” and “below,” “up” and “down,” “top” and “bottom,” and the like, are with gravitational reference when the present technology is in regular use. Thus, for example, a component is “above” another if, when the present technology is in regular use, that component is gravitationally higher than the other. Similarly, a first aspect may be considered “upper” and a second aspect may be considered “lower” when, in the regular use of the invention, the first aspect is gravitationally higher than the second aspect.

A panel frame is provided, of a design optimized for compact stacking during shipment.

The panel frame includes at least one primary beam and one secondary beam. The secondary beam may have at least one flat 40 formed at one end. In some embodiments, the secondary beam has a first flat 40 formed at one end and a second flat 40 formed at the other end.

A primary beam may be a first primary beam 21. The first primary beam 21 may define a first length. A second primary beam 22 may also be provided, which defines a second length. In some embodiments, the first and second lengths may be equal. Of those embodiments, with some the first primary beam 21 and the second primary beam 22 may be identical. With particular examples, a primary beam, such as the first primary beam 21 and/or the second primary beam 22, may be rectilinear. Likewise, with some examples, a primary beam, such as the first primary beam 21 and/or the second primary beam 22, may be hollow tubes while in other examples they may be solid. In certain applications, a primary beam such as the first primary beam 21 may define a circular cross-section, while in other examples it may define a rectangular cross-section, another polygonal cross-section, an oval cross-section, or a curvilinear cross-section, or the cross-section may change from one form to another along the length of the beam.

The first primary beam 21 and second primary beam 22 may reside parallel to each other in a single plane. Each of the first primary beam 21 and second primary beam 22 may define a beam maximum width perpendicular to the beam and parallel to the plane. The term open “maximum width” is intended to mean the greatest width as measured parallel to the plane.

A secondary beam, such as the first secondary beam 31, may be attached at the end of the first secondary beam 31 to the first primary beam 21 at a location along the length of the first primary beam 21. The first primary beam 21 may define a first maximum width 61 parallel to the first secondary beam 31 proximate to the attachment of the first secondary beam 31, and may define a third maximum depth 53 proximate to the attachment of the first secondary beam 31 and perpendicular to the first maximum width 61. The term open “maximum depth” is intended to mean the greatest depth as measured perpendicular to the plane.

The first secondary beam 31 may also be attached at its other end to a second primary beam 22. The second primary beam 22 may define a second maximum width 62 parallel to the first secondary beam 31 proximate to the attachment to the first secondary beam 31 and may define a fourth maximum depth 54 proximate to the attachment of the first secondary beam 31 and perpendicular to the second maximum width 62.

In some examples, a secondary beam, such as the first secondary beam 31, may be rectilinear. Likewise, with some examples, a secondary beam, such as the first secondary beam 31, may be a hollow tube, while in other examples it may be solid. In certain applications, a secondary beam such as the first secondary beam 31 may define a circular cross-section, while in other examples it may define a rectangular cross-section, another polygonal cross-section, an oval cross-section, or a curvilinear cross-section, or the cross-section may change from one form to another along the length of the beam.

A secondary beam, such as the first secondary beam 31, may include a first flat 40 proximate to the attachment of the first secondary beam 31 to the first primary beam 21. The first secondary beam 31 may define a first maximum depth 51 adjacent to the first flat 40, opposite the attachment to the first primary beam 21, and perpendicular to the first flat 40. The first flat 40 may define a flat depth 43 perpendicular both to the first primary beam 21 and to the first secondary beam 31. The flat depth 43 may be parallel to the third maximum depth 53. The flat depth 43 may be less than the first maximum depth 51. The flat 40 may define a flat length 44, the flat length 44 being parallel to and having a length of at least the first maximum width 61.

Consider that the first secondary beam 31 may also be attached at its other end to a second primary beam 22. In such a configuration, the first secondary beam 31 may include a second flat 40 proximate to the attachment of the first secondary beam 31 to the second primary beam 22. The first secondary beam 31 may define a second maximum depth 52 adjacent to the second flat 40, opposite the attachment to the second primary beam 22 and perpendicular to the second flat 40. The second flat 40 may define a flat length 44, the flat length 44 being parallel to and at end of a length at least that of the second maximum width 62. The second flat 40 may also define a flat depth 43 parallel to the fourth maximum depth 54, the flat depth 43 being less than the second maximum depth 52.

A flat 40 included at an end of a secondary beam may be of several configurations. That illustrated in the accompanying drawings is a flat 40 with two opposing parallel planes. Another configuration (not shown) has only a single plane. Indeed, in still other configurations (not shown), a flat 40 may be a curvilinear surface, or two parallel curvilinear surfaces. In all embodiments, though, the flat depth 43 of such a flat 40 will be less that the maximum depth of the secondary beam adjacent to the flat 40, opposite the attachment to a primary beam, and perpendicular to the flat 40.

In some embodiments, a secondary beam may reside perpendicular to a primary beam. In other embodiments, one secondary beam may reside perpendicular to a primary beam and another secondary beam may reside parallel to a primary beam. However, instill other embodiments, a secondary beam may reside at an oblique angle to one or more primary beam.

A secondary beam, such as the first secondary beam 31, may define a maximum depth adjacent to a flat 40, opposite the attachment of the secondary beam to a primary beam and parallel to the flat depth 43, the maximum depth being greater than the flat depth 43. In particular examples, the maximum depth may be greater than twice the flat depth 43.

Each flat 40 may define a flat depth 43 that is less than the maximum beam depth and may define a flat length 44 that is greater than the maximum width 61. In certain examples, the first maximum depth 51 may equal the first maximum width 61.

Some embodiments may include a second secondary beam 32, the second secondary beam 32 attached to the second primary beam 22 along the second length of the second primary beam 22. In particular embodiments, the second secondary beam 32 may be identical to the first secondary beam 31. In some applications, all of the secondary beams may be identical. In particular embodiments, the first secondary beam 31 and the second secondary beam 32 may both reside perpendicular to the first primary beam 21 and the second primary beam 22, and the second secondary beam 32 may be parallel to the first primary beam 21 and the second primary beam 22. In still further examples, a third secondary beam 33 may be attached to either the first secondary beam 31 or the second secondary beam 32 along a length of same.

Individual forms of the present technology may include the following features. The first maximum depth 51, the second maximum depth 52, and the first maximum width 61 may all be equal to one another. Additionally, or alternatively, the first primary beam 21 and the second primary beam 22 and the first secondary beam 31 and the second secondary beam 32 may each define a circular cross section; in particular examples all such cross sections may be the same cross-section.

The drawings illustrate certain aspects of the present technology.

FIG. 1A illustrates aspects of the prior art, in which a secondary beam A having a depth T1 is joined to a primary beam B having a depth of T2. Secondary beam A must first be notched so as to fit against the circular cross-section of the length of primary beam B. FIG. 1B illustrates a secondary beam A having been joined to a primary beam B by weldment W. It will be observed from FIGS. 1A and 1B that panels constructed by the methodology illustrated therein may be stacked together, but the height of such a stack would be the sum of the depths of the larger of the two members, primary beam B and secondary beam A, specifically T1 plus T2.

FIGS. 2A and 2B illustrate alternative embodiments of the present technology. In FIG. 2A, a first secondary beam 31, with a flat 40 at its end, is being joined with a first primary beam 21. In FIG. 2A, both the first primary beam 21 and the first secondary beam 31 define circular cross-sections. In FIG. 2B, likewise a first secondary beam 31, with a flat 40 at its end, is being joined with a first primary beam 21. In FIG. 2B, both the first primary beam 21 and the first secondary beam 31 define rectangular cross-sections. It will be observed from FIGS. 2A and 2B that panels constructed according to the present technology and illustrated therein may be stacked together and the height of such a stack would be less than that of a stack of prior art panels inasmuch as a primary beam 21 of a particular panel may be stacked against a flat 40, of lesser depth, of another panel rather than against the larger depth of a secondary beam.

FIG. 3 illustrates the joinder by weldment W of a first secondary beam 31, with a flat 40 at its end, to a first primary beam 21.

FIG. 4 illustrates an end view of a secondary beam, such as a first secondary beam 31. The first secondary beam 31 defines a first maximum depth 51 perpendicular to the face of a flat 40 that resides at the end of the first secondary beam 31. In turn, the flat 40 defines a flat depth 43, likewise perpendicular to the face of the flat 40. The flat 40 illustrated in FIG. 2 is a two-sided flat 40, but alternative embodiments include a one-sided flat 40. As illustrated in FIG. 4, first maximum depth 51 is greater than flat depth 43.

FIGS. 5A and 5B illustrate a top view of a first panel frame 11. The first panel frame 11 includes a first primary beam 21 and a second primary beam 22. The first panel frame 11 also includes a first secondary beam 31 that has a first flat 40 at its first end and a second flat 40 at its second end. As illustrated in FIG. 5A, but likewise applicable to the embodiment illustrated in FIG. 5B, the first primary beam 21 has a third maximum depth 53 and a first maximum width 61. The second primary beam 22 has a fourth maximum depth 54 and a second maximum width 62. The flat 40 at each end of the first secondary beam 31 has a flat depth 43 and a flat length 44. The first secondary beam 31 also has a first maximum depth 51 at its first end and a second maximum depth 52 at its second end. The embodiment illustrated in FIG. 5A is a first panel with a first primary beam 21 having a circular cross section and a second primary beam 22 having a circular cross section. The embodiment illustrated in FIG. 5B is a first panel with a first primary beam 21 and a second primary beam 22 each having a rectangular cross section. As illustrated in FIGS. 5A and 5B, flat depth 43 is lesser than first maximum depth 51, second maximum depth 52, third maximum depth 53, and fourth maximum depth 54.

FIG. 6 illustrates an example of a first panel frame 11 according to the subject invention. In the illustrated embodiment, the first panel frame 11 includes a first primary beam 21 and a second primary beam 22. A first secondary beam 31 that includes a flat 40a at one end and a flat 40d at its other end has been joined along the length of the first primary beam 21 and along the length of the second primary beam 22. A second secondary beam 32 that includes a flat 40b at one end and a flat 40e at the other end has likewise been joined along the length of the first primary beam 21 and along the length of the second primary beam 22. Still further, a third secondary beam 33 that has a flat 40c at one end and a flat 40f at the other end has been joined along the length of the first primary beam 21 and along the length of the second primary beam 22. It will be observed that the first panel frame 11 illustrated in FIG. 6 resides in a single plane. It will also be observed that the first secondary beam 31, the second secondary beam 32, and the third secondary beam 33 have been attached perpendicular to the first primary beam 21 and to the second primary beam 22.

FIG. 7 illustrates another example, of the seemingly endless possible combinations according to the subject invention, of a first panel frame 11. In the illustrated embodiment, a first primary beam 21 and a second primary beam 22 are provided. A first secondary beam 31 is attached to the first primary beam 21 and to the second primary beam 22. A sixth secondary beam 36 also is attached to the first primary beam 21 and to the second primary beam 22. A fourth secondary beam 34 and a fifth secondary beam 35 each are attached along the length of the first primary beam 21 and also are attached along the length of the sixth primary beam. A second secondary beam 32 is attached to the first primary beam 21 and to the fourth secondary beam 34. A third secondary beam 33 is attached to the fourth secondary beam 34 and to the fifth secondary beam 35.

The first secondary beam 31 has a flat 40g at one end and a flat 40j at the other end. The sixth secondary beam 36 has a flat 400 at one of its ends and a flat 40r at its other end. The fourth secondary beam 34 has a flat 48h at one of its ends and a flat 40p at its other end. The fifth secondary beam 35 has a flat 40l at one of its ends and a flat 40q at the other of its ends. The second secondary beam 32 has a flat 40k and a flat 40l at its respective ends. And the third secondary beam 33 has a flat 40m at one of its ends and a flat 40n at its other end. The entirety of the first panel frame 11 of FIG. 7 resides in a single plane. Each of the members—the primary beams and the secondary beams—are rectilinear.

FIG. 8 illustrates a stacking of two panel frames such as the configuration illustrated in FIG. 6. More specifically, FIG. 8 illustrates a stacking of a second panel frame 12 atop a first panel frame 11. According to the present invention, the first primary beam 21′ of the second panel frame 12 resides proximate to, and in some embodiments against, flat 40a, flat 40b, and flat 40c of the first panel frame 11. It will also be observed that the second primary beam 22 of the first panel frame 11 resides proximate to, and in some embodiments against, flat 40d′, flat 40e′, and flat 40f′ of second panel frame 12. Thus, the total stack height 80 of the second panel frame 12 and the first panel frame 11, as illustrated in FIG. 8, is less than the stack height of two panel frames constructed according to the prior art.

FIG. 9 illustrates a stacking of two panel frames such as the configuration illustrated in fig seven. More specifically, FIG. 9 illustrates a stacking of a second panel frame 12 atop a first panel frame 11. According to the present invention, first primary beam 21′ of these second panel frame 12 resides proximate to, and in some embodiments against, flat 40g, flat 40k, and flat 400 of the secondary beams of the first panel frame 11. Second primary beam 22 of the first panel frame 11 resides proximate to, and in some embodiments against, flat 40j′ and flat 40r′ of the second panel frame 12. The first secondary beam 31′ resides proximate to, and in some embodiments against, flat 40h and flat 40i of the first panel frame 11. The fourth secondary beam 34 of the first panel frame 11 resides proximate to, and in some embodiments against, flat 40l′ of the second panel frame 12. The fifth secondary beam 35 of the first panel frame 11 resides proximate to, and in some embodiments against, flat 40n′ of the second panel frame 12. The sixth secondary beam 36 of the first panel resides proximate to, and in some embodiments against, flat 40p′ and flat 40q′ of the second panel frame 12. Thus, the total stack height 80 of the second panel frame 12 and the first panel frame 11, as illustrated in FIG. 9, is less than the stack height of two similar panel frames constructed according to the prior art.

FIGS. 10A and 10B illustrate some of the advantages of the present invention. FIGS. 10A and 10B are a top view of a third panel frame 13 that has been stacked atop a second panel frame 12, which has been stacked atop a first panel frame 11. In FIG. 10A, the primary beams 21, 22, and 23 have a circular cross-section; in FIG. 10B, the primary beams 21, 22, and 23 have a rectangular cross-section. The third panel frame 13 includes a third secondary beam 33 and a flat 40 at the end of the third secondary beam 33, the flat 40 having been attached to a third primary beam 23. The second panel frame 12 includes a second secondary beam 32 with a flat 40 at the end of the second secondary beam 32, the flat 40 having been attached to a second primary beam 22. The panel frame includes a first secondary beam 31 with a flat 40 at the end of the first secondary beam 31, the flat 40 having been attached to a first primary beam 21. The first primary beam 21, which also is representative of the second primary beam 22 and the second primary beam 22, has a third maximum depth 53 and a first maximum width. So configured, and stacked as illustrated in FIGS. 10A and 10B, the three panel frames have a stack height 80 that is less than the stack height of three panel frames constructed according to the prior art. More specifically as to the illustrations of FIGS. 10A and 10B, the stack height 80 of panels 11, 12, and 13 is about twice the third maximum depth 53, whereas the stack height of such three panels configured according to the prior art would be about triple the third maximum depth 53.

FIGS. 11 and 12 are perspective view illustrating uses of an embodiment of the present invention, specifically animal kennels.

It should be appreciated that, in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not be interpreted as reflecting an intention that any claim requires more features than are expressly recited in that claim. Moreover, any components, features, or steps illustrated and/or described in a particular embodiment herein, can be applied to or used with any other embodiment. Thus, it is intended that the scope of the inventions herein disclosed should not be limited by the particular embodiments described above, but should be determined only by a fair reading of the claims that may issue from the benefit of the within disclosure.

Claims

1. A panel frame optimized for compact stacking during shipment, comprising:

first and second primary beams residing parallel to each other and residing in a plane, each defining a beam maximum width perpendicular to the beam and parallel to the plane;

a plurality of secondary beams, each secondary beam:

defining a beam maximum depth perpendicular to the plane;

having a flat on both ends, each flat defining a flat depth that is less than the beam maximum depth and defining a flat length that is greater than the beam maximum width; and

each flat attached at its end either to a primary beam along its length or to a secondary beam along its length.

2. The panel frame of claim 1, in which all secondary beams are identical.

3. The panel frame of claim 1, in which all secondary beams reside perpendicular to the primary beams.

4. The panel frame of claim 1, in which at least one of the secondary beams is perpendicular to the primary beams and at least one of the secondary beams is parallel to the primary beams.

5. The panel frame of claim 1, in which the first and second primary beams define the beam maximum depth.

6. The panel frame of claim 1, in which each of the secondary beams define a width equal to the beam maximum width.

7. The panel frame of claim 1, in which the primary beams and the secondary beams have a circular cross-section.

8. Panel frames optimized for compact stacking during shipment, comprising:

a first panel frame that includes a first primary beam, the first primary beam defining a first length;

a second panel frame that includes a second primary beam, the second primary beam defining a second length;

a first secondary beam:

attached to the first primary beam along the first length;

including a flat proximate to the attachment of first secondary beam to the first primary beam, the flat defining a flat depth perpendicular to both the first primary beam and the first secondary beam;

defining a maximum depth adjacent to the flat, opposite the attachment to the first primary beam and parallel to the flat depth, the maximum depth being greater than the flat depth;

a second secondary beam, the second secondary beam attached to the second primary beam along the second length;

the second primary beam residing parallel to the first primary beam and in contact with the flat.

9. The panel frames of claim 8, in which the contact is direct contact.

10. The panel frames of claim 8, in which the second secondary beam is identical to the first secondary beam.

11. The panel frames of claim 8, in which first and second primary beams and the first and second secondary beams each define a circular cross-section.

12. The panel frames of claim 8, in which the first and second secondary beams are both perpendicular to the first primary beam.

13. The panel frames of claim 8, in which the maximum depth is greater than twice the flat depth.

14. The panel frames of claim 8, further including a third secondary beam, the third secondary beam attached to the first secondary beam.

15. A panel frame optimized for compact stacking during shipment, comprising:

a first primary beam, the first primary beam defining a first length;

a second primary beam, the second primary beam defining a second length;

a first secondary beam, the first secondary beam:

attached to the first primary beam along the first length;

attached to the second primary beam along the second length;

including a first flat proximate to the attachment of first secondary beam to the first primary beam;

defining a first maximum depth adjacent to the first flat, opposite the attachment to the first primary beam, and perpendicular to the first flat;

including a second flat proximate to the attachment of the first secondary beam to the second primary beam;

defining a second maximum depth adjacent to the second flat, opposite the attachment to the second primary beam, and perpendicular to the second flat;

the first primary beam defining a first maximum width parallel to the first secondary beam at the attachment to the first secondary beam and defining a third maximum depth at the attachment to the first secondary beam and perpendicular to the first maximum width;

the second primary beam defining a second maximum width parallel to the first secondary beam at the attachment to the first secondary beam and defining a fourth maximum depth at the attachment to the first secondary beam perpendicular to the second maximum width;

the first flat:

defining a first flat length, the first flat length being parallel to and at least as long as the first maximum width; and

defining a first flat depth parallel to the third maximum depth, the first flat depth being less than the first maximum depth;

the second flat:

defining a second flat length, the second flat length being parallel to and at least as long as the second maximum width; and

defining a second flat depth parallel to the fourth maximum depth, the second flat depth being less than the second maximum depth.

16. The panel frame of claim 15, in which the first and second primary beams are identical.

17. The panel frame of claim 15, in which the first maximum depth equals the first maximum width.

18. The panel frame of claim 15, in which the first maximum depth, the second maximum depth, and the first maximum width are equal.

19. The panel frame of claim 15, further including a second secondary beam, the second secondary beam identical to the first secondary beam and attached to the first primary beam and to the first secondary beam.

20. The panel frames of claim 15, in which the maximum depth is greater than twice the flat depth.