Shipping container

Abstract

 A shipping container includes a rigid frame (10) and a sack (11) of flexible material removably supported by and within the frame. The rigid frame is of polygonal configuration and includes a plurality of vertical posts (12), a plurality of lower horizontal bars (13) interconnecting the lower ends of the vertical posts but spaced slightly upwardly thereof to provide space for receiving the jaws of a forklift truck, and a plurality of upper horizontal bars (14) interconnecting the upper ends of the vertical posts for removably receiving the upper end (17) of the sack and for supporting it in suspension with the bottom of the sack raised above the bottom of the lower horizontal bars.

Description

[0001] The present invention relates to shipping containers, and particularly to containers used for shipping various types of products, both solid products and liquids.

[0002] At the present time, solid and liquid products are commonly shipped by means of sacks, boxes or barrels. Sacks, of the type commonly called "big bags", are the least expensive and have no return costs, since they are usually used only one time. However, sacks have minimum dimensional stability, and therefore provide very little protection against physical damage to the products being shipped; they are also difficult to stack, and may damage the products by wetting if stacked on the ground. Boxes provide somewhat more dimensional stability and protection, but are considerably more expensive particularly if used for one-time only; if produced for multi-time use, they take-up considerable volume when returning empty or for storage, and if constructed in a collapsible form for this purpose, they usually do not permit sealing the contents. Barrels provide the maximum dimensional protection and stability, but are very expensive to produce, generally require cleaning after each use, and have high return costs.

[0003] An object of the present invention is to provide a shipping container having advantages in the above respects.

[0004] According to the present invention, there is provided a shipping container comprising a rigid frame and a sack of flexible material removably supported by and within said frame; said rigid frame being of polygonal configuration and including: a plurality of vertical posts; a plurality of lower horizontal bars interconnecting the lower ends of the vertical posts but spaced slightly upwardly thereof to provide space for receiving the jaws of a forklift truck; and a plurality of upper horizontal bars interconnecting the upper ends of the vertical posts for removably receiving the upper end of the sack and for supporting it in suspension with the bottom of the sack raised above the bottom of the lower horizontal bars.

[0005] According to the described preferred embodiment, the upper and lower ends of the vertical bars include mating formations permitting like frames to be vertically stacked one on top of the other.

[0006] It will thus be seen that a shipping container constructed in accordance with the foregoing features provides high dimensional stability, protection, and ease of handling. It is also less costly since the rigid frame is reused and only the sacks may be disposed of, in which case it minmizes or obviates recleaning between uses. The rigid frame may be of a construction which is collapsible or which can be easily assembled and disassembled, thereby minimizing return-empty costs. As will be described below, when the rigid frame is in a collapsible form, it still permits sealing of the contents during the normal use of the container.

[0007] Further features and advantages of the invention will be apparent from the description below.

[0008] The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:

Figs. 1-4 illustrate four forms of shipping containers constructed in accordance with the invention, Fig. 3a illustrating the folded condition of the shippng container of Fig. 3;

Figs. 5a-5d are fragmentary views illustrating various stages in collapsing the rigid frame of a still further form of shipping container constructed in accordance with the invention;

Fig. 6 illustrates a further variation wherein the frame is of a hexagonal configuration.

Fig. 7 illustrates a further variation wherein the sack used in the shipping container is closed at both ends (or only at one end) by a drawstring; and

Figs. 8a-8c are fragmentary views illustrating various manners of securing the sack to the rigid frame.

[0009] The shipping container illustrated in Fig. 1 comprises a rigid frame, generally designated 10, of rectangular (preferably square) configuration, and a sack 11 of flexible material removably supported by and within the frame. The frame includes four vertical posts 12, one at each of the four corners of the frame; four lower horizontal bars 13 interconnecting the lower ends of posts 12; and four upper horizontal bars 14 interconnecting the upper ends of posts 12. The lower horizontal bars 13 are spaced upwardly from the lower ends of the vertical posts 12 a distance, equal to the lengths of the lower sections 12a of the posts, to provide a space for receiving the jaws of a forklift truck. The upper horizontal bars 14 are spaced slightly downwardly from the upper ends of the vertical posts 12, to provide upper extensions 12b at the upper ends of the posts to enable another like shipping container to be stacked on top of the respective container without contact with the sack 11 supported within the respective container.

[0010] To permit such vertical stacking, the lower ends of each of the four vertical posts 12 terminates in feet 16 having mating formations with respect to the upper ends 12b of the vertical posts 12. For example, each foot 16 may be formed with a recess (as shown at 76a in Fig. 5a) complementary to the cross-section of the upper ends 12b of the vertical posts 12. For purposes of example, the vertical bars 12, as well as the horizontal bars 13 and 14, are all of hollow rectangular cross-section, so that the mating formation of the feet 16 would be in the form of a recess of complementary rectangular configuration.

[0011] In the example illustrated, the sack 11 includes four hangers or rings 17 at its four corners. Each ring 17 is receivable over the upper extension 12b of its respective vertical post 12 in order to support the sack in suspension within the rigid frame 10. Rings 17 also enable the sack to be lifted out of its respective rigid frame, manually or by a powered lifting device. Sack 11 is so dimensioned such that, when supported in suspension in the frame 10, its bottom is raised from the ground, preferably at about the level of the lower horizontal bars 13. This permits a forklift truck to handle a full container by applying its jaws in the space between feet 16 and the lower horizontal bars 13 of the rigid frame. This arrangement also prevents direct contact between the bottom of the sack and ground, thereby preventing wetting or other damage to the container contents normally caused by such ground contact.

[0012] It will thus be seen that the shipping container illustrated in Fig. 1 provides dimensional stability to the shipping container, permitting it to be stacked both vertically and horizontally with other like containers; provides substantial protection against damage to the products contained within the sack 11; and permits the use of low-cost disposable sacks, thereby minimizing the need for cleaning during reuse. The rigid frame 10 may also be constructed in a collapsible or disassemblable manner, as will be described more particularly below, to reduce the volume of the rigid frame for purposes of storage, handling or return-empty shipping when not in use. In addition, the sack permits sealing of the contents of the shipping container, which heretofore has been difficult if possible at all in a shipping container of the collapsible type.

[0013] Fig. 2 illustrates a shipping container which includes a rigid frame 20 of similar cosntruction as frame 10 in Fig. 1, but supports two (or more) sacks 21a, 21b in vertically-spaced relation within the rigid frame.

[0014] More particularly, the rigid frame 20 in Fig. 2 also includes four vertical posts 22, one at each of its four corners; four lower horizontal bars 23, interconnecting the lower ends of the posts but spaced slightly upwardly to provide space for receiving the jaws of a forklift truck; and four upper horizontal bars 24 interconnecting the upper ends of the vertical posts. The shipping container of Fig. 2 further includes four intermediate bars 25 interconnecting intermediate parts of the vertical posts 22. Feet 26 are applied to the lower ends of the four vertical posts 22 and are also provided with mating formations (e.g., rectangular-shaped recesses as shown in Fig. 7a) cooperable with the upper ends of the vertical posts 22, to permit vertical stacking of like shipping containers.

[0015] The shipping container illustrated in Fig. 2 also includes a different arrangement for attaching the two vertically-spaced sacks 21a, 21b to the rigid frame 20. Thus, each sack 21a, 21b is provided with sleeves 27a, 27b receivable over horizontal bars 24, 25, for supporting their respective sack in suspension within the rigid frame 20. The upper sack 21a is supported in this manner from the upper horizontal bars 24 with the bottom of the sack slightly above the level of the intermediate horizontal bars 25, whereas the lower sack 21b is supported from the intermediate horizontal bars 25 with the bottom of that sack substantially at the level of the lower horizontal bars 23 to provide a space for the jaws of a forklift truck.

[0016] It will be appreciated that the shipping container of Fig. 2 may have more than two sacks, which is particularly advantageous in shipping delicate products, such as produce. At the present time, such products are shipped in shallow boxes, which are relatively expensive because the cost of the bottom is approximately 50% of the total box cost.

[0017] Fig. 3 illustrates another shipping container which also includes a rigid frame 30 and a sack of flexible material 31 removably supported by and within the frame, similar to the structure illustrated in Fig. 1, except that the sack is supported by means of sleeves 37 formed in the open end of the sack, similar to the arrangement illustrated in Fig. 2. Another difference in Fig. 3 over that of Figs. 1 and 2 is that the rigid frame 30 is of a foldable or collapsible construction, enabling it to be folded into compact form for shipment or storage when not in use. It also includes reinforcing the wires 38 reinforcing its bottom and its four walls.

[0018] To provide the collapsible construction, the lower horizontal bars 33 are pivotally mounted to each other and to their respective vertical posts 32 by hinges 33a, and the upper horizontal bars 34 are similarly mounted to the vertical posts 32 by hinges 34a. Any suitable retainer means, such as retainer recesses and projections, may be provided in the hinges 33a, 34a for releasably retaining the shipping container in its open operative position as illustrated in Fig. 3 but permitting the frame 30 to be moved to a folded condition by pivotting the opposite vertical posts 32, 32 towards each other to fold the frame into a flat, two-layer condition for shipment or storage, as illustrated in Fig. 3a.

[0019] It will be appreciated that the above-­described foldable construction of Fig. 3 may also be used in the previously-described constructions of Figs. 1 and 2. When the foldable construction is provided in the shipping container of Fig. 2, the intermediate horizontal bars 25 would likewise be pivotally mounted to each other and to their respective vertical posts 22. It will also be appreciated that the suspension rings 17 provided in the shipping container of Fig. 1 may also be provided in the shipping container of Fig. 3 (as well as that of Fig. 2) instead of (or in addition to) the sleeves, in order to facilitate removal of the sacks with their contents from their respective rigid frames.

[0020] Fig. 4 illustrates another shipping container, which includes a rigid frame 40 which may be disassembled to reduce its volume for shipping or storing when not in use. Thus, the rigid frame 40 includes four vertical posts 42, four lower horizontal bars 43, and four upper horizontal bars 44, the latter supporting the sack 41 in suspension within the frame by the use of sleeves 47, or any other manner described herein.

[0021] To permit disassembly of the rigid frame 40, the four vertical posts 42 are made in two sections 42a, 42b. The lower section 42b is integrally formed with the four lower horizontal bars 43 and with the feet 46 and is attachable by a telescoping fit into the lower ends of the post sections 42a. In addition, the four upper horizontal bars 44 are integrally formed as a single unit and are attachable to the upper ends of the post sections 42a. Appropriate fasteners (not shown) may be used for securing the lower section 42b including the lower bars 43, to the lower ends of their respective vertical posts 42a, and for securing the upper section including the four upper horizontal bars 44, to the upper ends of the vertical post sections 42a.

[0022] Sack 41 is supported in suspension from the upper horizontal bars 44 by the use of sleeves 47. However, the sack further includes rings 48, at each of its four corners, similar to the rings 17 in Fig. 1, to facilitate lifting and handling the sack and its contents.

[0023] Figs. 5a-5d illustrate another collapsible construction for the rigid frame, generally designated 50, and particularly the various stages involved during the collapsing of the frame. When in its normal operative position, frame 50 would also support a sack (not shown) in any of the manners described above (or below), but the frame may be collapsed into a compact form for return-empty shipment, storage or handling when not in use.

[0024] More particularly, frame 50 also includes four vertical posts, each generally designated 52, at its four corners, four lower horizontal bars 53 interconnecting the lower ends of the posts, and four upper horizontal bars 54 interconecting the upper ends of the posts. Each of the vertical posts 52, however, includes three sections, namely a link 52a, a lower section 52b, and an upper section 52c. The lower section 52b is joined to the lower horizontal bars 53 and the feet 56 so as to constitute a single integral unit; and the upper post section 52c is similarly joined to the four upper horizontal bars 54 so as to constitute a single integral unit.

[0025] The middle section 52a of each post is pivotally mounted by a link 52d to the respective lower horizontal bar 53; and the upper end of each link 52a is pivotally mounted by a pin 52e to the upper post section 52c integrally formed with the upper horizontal bars 54. Both the lower post section 52b and upper post section 52c are hollow so as to permit the end of the respective link 52a to seat within it. In addition, pivot pin 52e at the upper end of each link 52a moves in an elongated slot 52f formed in the link, to permit the link to move a small distance parallel to its longitudinal axis.

[0026] Fig. 5a illustrates the operative position of the rigid frame 50, wherein the link 52a of each of the vertical posts 52 at the four corners of the frame assumes a vertical position, with the lower end of the link received within the lower section 52b, and the upper end of the link received within the upper section 52c. Such a construction stably supports the rigid frame in its open operative position.

[0027] When it is desired to collapse the frame for purposes of return-empty shipment, the upper section 52c of the frame, secured to the upper horizontal bars 54, is lifted upwardly to unseat the lower end of link 52a from the lower section 52b, and is then moved laterally to pivot link 52a clear of the lower section 52b. The upper section 52c is then moved downwardly, as shown in Fig. 5c, while the links 52a are further pivotted, until the links 52a are moved to horizontal positions, as shown in Fig. 5d. In this position the lower end of section 52c now engages the upper end of section 52b.

[0028] Fig. 5a illustrates the recess 56a formed in the bottom face of each of the feet 56, which is complementary to the upper ends of the vertical posts, in order to permit vertical stacking of like containers. Fig 5b illustrates a hook 58 which may be provided in the upper face of the upper horizontal bars 54 for receiving the jaws of a forklift truck, it being appreciated that the same structure may also be included in the other described embodiments.

[0029] Fig. 6 illustrates a shipping container including a rigid frame 60 of a hexagonal configuration, rather than of a square configuration. The sack 61 supported by and within the frame 60 may be of a similar hexagonal configuration, or of a circular configuration.

[0030] Thus, frame 60 includes six vertical posts 62, six lower horizontal bars 63, and six upper horizontal bars 64, all interconnected according to any of the above-described constructions, e.g., to permit folding as described with respect to Figs. 3, or 5a-5d, or disassembly as described with respect to Fig. 4. Such a hexagonal construction also enables horizontal nesting in side-by-side relationship, and vertical stacking, but permits the sack 61 to assume a closer configuration to the optimum circular configuration for maximum volume and maximum strength.

[0031] In all the above-described constructions, the sacks are open at the top and closed at their bottoms. Fig. 7 illustrates another construction wherein the sacks are normally open at their upper and lower ends but are closed by drawstrings. Thus, the shipping container illustrated in Fig. 7 also includes a rigid frame, generally designated 70, which for purposes of example is of the construction illustrated in Fig. 2 for supporting two vertically-spaced sacks 71a, 71b. One or both of the sacks may be of the construction illustrated by sack 71a, which is open at its upper and/or lower ends, but closed by drawstrings 77, 78, respectively.

[0032] Figs. 8a-8c illustrate other means which may be used in liew of, or in addition to, the above-­described means for suspending the sacks within their rigid frames. Thus, as shown in Fig. 8a, sack 81 is formed with an extension 81a at its upper end which is wrapped around its respective upper horizontal bar 84 and terminates in a loop or hook 81b received within pin or extension 84a projecting from the underface of bar 84. Fig. 8b illustrates the sack 91 formed with an upper extension 91a wrapped around the upper horizontal bar 94 and terminating in an extension 91b which is clamped between the extension and the bar. Fig. 8c illustrates an arrangement similar to that of Fig. 8b, except that the thickned outer edge 91b′ of the extension 91a′ is received within a slot 94a formed in the upper horizontal bar 94. All the foregoing arrangements are intended to permit the sack to be conveniently applied and removed from its respective frame.

[0033] While the invention has been described with respect to several preferred embodiments, it will be appreciated that these are shown purely for purposes of example, and that many other variations, modifications and applications of the invention may be made.

[0034] Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.

Claims

1. A shipping container comprising a rigid frame and a sack of flexible material removably supported by and within said frame; said rigid frame being of polygonal configuration and including: a plurality of vertical posts; a plurality of lower horizontal bars interconnecting the lower ends of the vertical posts but spaced slightly upwardly thereof to provide space for receiving the jaws of a forklift truck; and a plurality of upper horizontal bars interconnecting the upper ends of the vertical posts for removably receiving the upper end of the sack and for supporting it in suspension with the bottom of the sack raised above the bottom of the lower horizontal bars.

2. The shipping container according to Claim 1, wherein the upper and lower ends of said vertical bars include mating formations permitting like frames to be vertically stacked one on top of the other.

3. The shipping container according to either of Claims 1 or 2, wherein said frame is of rectangular configuration.

4. The shipping container according to either of Claims 1 or 2, wherein said frame is of hexagonal configuration.

5. The shipping container according to any one of Claims 1-4, wherein all the upper horizontal bars are joined together, and all the lower horizontal bars are joined together; and wherein the upper ends of the vertical bars are pivotal to said upper horizontal bars, and the lower ends of the vertical bars are pivotal to said lower horizontal bars and are also nestable therein, such as to permit the upper horizontal bars to move against the lower horizontal bars into a compact form for return-empty shipping or storage.

6. The shipping container according to any one of Claims 1-4, wherein said horizontal bars are pivotally mounted to each other and to the vertical posts, thereby permitting two opposed vertical posts to be pivotted towards each other to a folded condition for return-empty shipping or storage.

7. The shipping container according to any one of Claims 1-4, wherein said upper and lower horizontal bars are detachably mounted to said vertical bars thereby permitting the frame to be conveniently assembled and disassembled.

8. The shipping container according to any one of Claims 1-4, wherein said rigid frame further includes a plurality of intermediate horizontal bars interconnecting an intermediate part of the vertical posts, and a second sack of flexible material removably supported by and within said frame between the intermediate and lower horizontal bars, said first-­mentioned sack being removably supported by and within said frame between said intermediate and upper horizontal bars.

9. The shipping container according to any one of Claims 1-8, wherein at least one end of said sack is closed by a drawstring.

10. The shipping container according to any one of Claims 1-9, wherein the upper end of said sack includes a plurality of rings, one for and receivable over the upper end of each of said vertical posts, for supporting the sack in suspension within the rigid frame, and for aiding in removing it from the frame.

Drawing