[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S.

Provisional Application Serial No. 62/427,404 filed on November 29, 2016, the content of which is relied upon and incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present specification generally relates to crate assemblies for use in transporting spools of ultra-thin glass and to methods of transporting spools of ultra-thin glass using the bulk spool crate assemblies.

BACKGROUND

[0003] Current shipping crates used to ship bulk flexible glass wound on a spool may not adequately protect glass spools from damage and the resulting lower utilization of produced glass. Glass spools may be subjected to unintended levels of acceleration and vibration during shipping that can result in damage to the glass and cause increased cost to the manufacturer or customer. For example, relatively high levels of acceleration or vibration may occur during an impact to the shipping crates such as when crates are dropped or mishandled e.g., with a forklift.

[0004] Accordingly, a need exists for crate assemblies and methods of transporting spools of ultra-thin glass that can reduce acceleration and vibration experienced by the glass product due to an impact, which can reduce a likelihood of damage to the glass.

SUMMARY

[0005] According to a first embodiment, a crate assembly comprises:

an external crate assembly having a top, a bottom, sides and ends, the sides and ends extending between the top and the bottom;

an internal spool support assembly located within the external crate assembly, the internal spool support assembly comprising a lower spool support structure comprising:

a first lower spool support assembly located at one of the ends of the external crate assembly, the first lower spool support assembly having a spool-core receiving notch extending therethrough and sized to receive a spool core end; and a second lower spool support assembly located at an opposite one of the ends of the external crate assembly, the second lower spool support assembly having a spool-core receiving notch extending therethrough and sized to receive an opposite spool core end such that the spool core is arranged substantially perpendicular to the ends;

wherein the first lower spool support assembly is separated from the bottom of the external crate assembly by an isolation pad positioned between the first lower spool support assembly and the bottom of the external crate assembly and the second lower spool support assembly is separated from the bottom of the external crate assembly by an isolation pad positioned between the second lower spool support assembly and the bottom of the external crate assembly, and the first lower spool support assembly is separated from the second lower spool support assembly such that the first and second spool support assemblies are movable relative to each other.

[0006] According to a second embodiment, there is provided the crate assembly of embodiment 1, wherein the first lower spool support assembly is separated from the sides of the external crate assembly using isolation pads located between the first lower spool support assembly and the sides.

[0007] According to a third embodiment, there is provided the crate assembly of embodiment 1 or embodiment 2, wherein the second lower spool support assembly is separated from the sides of the external crate assembly using isolation pads located between the second lower spool support assembly and the sides.

[0008] According to a fourth embodiment, there is provided the crate assembly of any one of embodiments 1-3, wherein the first lower spool support assembly is separated from the one of the ends using an isolation pad located between the first lower spool support assembly and the one of the ends.

[0009] According to a fifth embodiment, there is provided the crate assembly of embodiment 4, wherein the first lower spool support assembly is separated from the one of the ends using multiple, vertically oriented isolation pads that are spaced-apart from one another in a lateral direction.

[0010] According to a sixth embodiment, there is provided the crate assembly of embodiment 4 or embodiment 5, wherein the second lower spool support assembly is separated from the opposite one of the ends using an isolation pad located between the second spool support assembly and the opposite one of the ends. [0011] According to a seventh embodiment, there is provided the crate assembly of embodiment 6, wherein the second lower spool support assembly is separated from the opposite one of the ends using multiple, vertically oriented isolation pads that are spaced- apart from one another in a lateral direction.

[0012] According to an eighth embodiment, there is provided the crate assembly of any one of embodiments 1-7, further comprising an upper spool support assembly comprising:

a first upper spool support assembly located at the one of the ends of the external crate assembly; and

a second upper spool support assembly located at the opposite one of the ends of the external crate assembly;

wherein the first upper spool support assembly is separated from the top of the external crate assembly by an isolation pad positioned between the first upper spool support assembly and the top of the external crate assembly and the second upper spool support assembly is separated from the top of the external crate assembly by an isolation pad positioned between the second upper spool support assembly and the top of the external crate assembly.

[0013] According to a ninth embodiment, there is provided the crate assembly of embodiment 8, wherein the first upper spool support assembly is separated from the one of the ends an isolation pad located between the first lower spool support assembly and the one of the ends.

[0014] According to a tenth embodiment, there is provided the crate assembly of embodiment 9, wherein the first upper spool support assembly is separated from the one of the ends using multiple, vertically oriented isolation pads that are spaced-apart from one another in a lateral direction.

[0015] According to an eleventh embodiment, there is provided the crate assembly of embodiment 9 or embodiment 10, wherein the second upper spool support assembly is separated from the opposite one of the ends using an isolation pad located between the second upper support assembly and the opposite one of the ends.

[0016] According to a twelfth embodiment, there is provided the crate assembly of embodiment 11, wherein the second upper spool support assembly is separated from the opposite one of the ends using multiple, vertically oriented isolation pads that are spaced- apart from one another in a lateral direction. [0017] According to a thirteenth embodiment, there is provided the crate assembly of any one of embodiments 1-12, wherein the isolation pads comprise polyethylene foam.

[0018] According to a fourteenth embodiment, there is provided the crate assembly of any one of embodiments 1-13, further comprising a spool of ultra-thin glass weighing 227 kg weight (500 pounds) or more located therein, the spool of ultra-thin glass including a spool core having a first core end received within the spool-core receiving notch of the first lower spool support assembly and an opposite second core end received within the spool-core receiving notch of the second lower spool support assembly, the isolation pad positioned between the first lower spool support assembly and the bottom maintaining separation between the first lower spool support assembly and the bottom with the first core end received within the spool-core receiving notch of the first lower spool support assembly.

[0019] According to a fifteenth embodiment, a method of shipping a spool of ultra- thin glass comprises:

placing a core into a crate assembly, the core comprising a first core end, a second core end, and ultra-thin glass rolled thereon, the crate assembly comprising:

an external crate assembly having a top, a bottom, sides and ends, the sides and ends extending between the top and the bottom;

an internal spool support assembly located within the external crate assembly, the internal spool support assembly comprising a lower spool support structure comprising:

a first lower spool support assembly located at one of the ends of the external crate assembly, the first lower spool support assembly having a spool- core receiving notch extending therethrough and sized to receive a spool core end; and

a second lower spool support assembly located at an opposite one of the ends of the external crate assembly, the second lower spool support assembly having a spool -core receiving notch extending therethrough and sized to receive an opposite spool core end such that the spool core is arranged substantially perpendicular to the ends;

wherein the first lower spool support assembly is separated from the bottom of the external crate assembly by an isolation pad positioned between the first lower spool support assembly and the bottom of the external crate assembly and the second lower spool support assembly is separated from the bottom of the external crate assembly by an isolation pad positioned between the second lower spool support assembly and the bottom of the external crate assembly, and the first lower spool support assembly is separated from the second lower spool support assembly such that the first and second spool assemblies are movable relative to each other;

locating the first core end of the spool core within the spool-core receiving notch of the first lower spool support assembly; and

locating the second core end of the spool core within the spool-core receiving notch of the second lower spool support assembly.

[0020] According to a sixteenth embodiment, there is provided the method of embodiment 15, wherein the first lower spool support assembly is separated from the sides of the external crate assembly using isolation pads located between the first lower spool support assembly and the sides.

[0021] According to a seventeenth embodiment, there is provided the method of embodiment 15 or 16, wherein the second lower spool support assembly is separated from the sides of the external crate assembly using isolation pads located between the second lower spool support assembly and the sides.

[0022] According to an eighteenth embodiment, there is provided the method of any one of embodiments 15-17, wherein the first lower spool support assembly is separated from the one of the ends using an isolation pad located between the first lower spool support assembly and the one of the ends.

[0023] According to a nineteenth embodiment, there is provided the method of embodiment 18, wherein the first lower spool support assembly is separated from the one of the ends using multiple, vertically oriented isolation pads that are spaced-apart from one another in a lateral direction.

[0024] According to a twentieth embodiment, there is provided the method of embodiment 18 or embodiment 19, wherein the second lower spool support assembly is separated from the opposite one of the ends using an isolation pad located between the second spool support assembly and the opposite one of the ends.

[0025] According to a twenty-first embodiment, there is provided the method of embodiment 20, wherein the second lower spool support assembly is separated from the opposite one of the ends using multiple, vertically oriented isolation pads that are spaced- apart from one another in a lateral direction. [0026] According to a twenty-second embodiment, there is provided the method of any one of embodiments 15-21, further comprising an upper spool support assembly comprising:

a first upper spool support assembly located at the one of the ends of the external crate assembly; and

a second upper spool support assembly located at the opposite one of the ends of the external crate assembly;

wherein the first upper spool support assembly is separated from the top of the external crate assembly by an isolation pad positioned between the first upper spool support assembly and the top of the external crate assembly and the second upper spool support assembly is separated from the top of the external crate assembly by an isolation pad positioned between the second upper spool support assembly and the top of the external crate assembly.

[0027] According to a twenty-third embodiment, there is provided the method of any one of embodiments 15-22, wherein the isolation pads comprise polyethylene foam.

[0028] According to a twenty-fourth embodiment, there is provided the method of any one of embodiments 15-23, wherein the spool of ultra-thin glass weighs 227 kg weight (500 pounds) or greater, the isolation pad positioned between the first lower spool support assembly and the bottom separating the first lower spool support assembly and the bottom with the first core end received within the spool-core receiving notch of the first lower spool support assembly.

[0029] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as exemplified in the written description and the appended drawings and as defined in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims.

[0030] The accompanying drawings are included to provide a further understanding of principles of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain, by way of example, principles and operation of the embodiments described herein. It is to be understood that various features disclosed in this specification and in the drawings can be used in any and all combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG. 1 depicts a perspective view of a bulk crate assembly for shipping ultra- thin glass spools, according to one or more embodiments shown and described herein;

[0032] FIG. 2 depicts a side view of the bulk crate assembly of FIG. 1 with a top and side removed, according to one or more embodiments shown and described herein;

[0033] FIG. 3 depicts an end view of the crate assembly of FIG. 1 with upper and lower outer wall members removed, according to one or more embodiments shown and described herein;

[0034] FIG. 4 depicts an end view of the crate assembly of FIG. 1 with upper and lower outer wall members removed, according to one or more embodiments shown and described herein; and

[0035] FIG. 5 depicts a section view of the bulk crate assembly of FIG. 1 with a spool of ultra-thin glass, according to one or more embodiments shown and described herein.

DETAILED DESCRIPTION

[0036] In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth to provide a thorough understanding of various principles of the present disclosure. However, it will be apparent to one having ordinary skill in the art, having had the benefit of the present disclosure, that the present disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, wherever applicable, like reference numerals refer to like elements.

[0037] As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term "about" is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites "about," the numerical value or end-point of a range is intended to include two embodiments: one modified by "about," and one not modified by "about." It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0038] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0039] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.

[0040] As used herein, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a "component" includes embodiments having two or more such components, unless the context clearly indicates otherwise.

[0041] Embodiments described herein relate generally to crate assemblies for use in transporting spools of ultra-thin glass and to methods of transporting spools of ultra-thin glass using the crate assemblies. The crate assemblies include an external crate assembly that has an internal spool support assembly located therein. The internal spool support assembly includes isolation pads positioned between the internal spool support assembly and the external crate assembly to facilitate damped movement of the internal spool support assembly relative to the external crate assembly. This damped movement of the internal spool support assembly within the external crate assembly can allow the spool of ultra-thin glass to float within the external crate assembly. Such a floating arrangement for the spool of ultra-thin glass within the external crate assembly can reduce acceleration and vibration experienced by the spool of ultra-thin glass due to, for example, an impact to the external crate assembly during an impact event.

[0042] Without wishing to be bound by theory, it has been discovered that spools of ultra-thin glass (e.g., glass of about 0.3 mm or less in thickness) within conventional shipping crates can experience damage under accelerations of about 70 times the acceleration due to gravity during impact testing. On the other hand, it is believed that spools of ultra-thin glass exhibit significantly reduced likelihood of damage under accelerations of less than or equal to about 20 times the acceleration due to gravity. Such reduced accelerations can be accomplished by applying a smaller force to the spool of ultra-thin glass over a longer period of time compared to a larger force over a shorter period of time.

[0043] As used herein, the term "longitudinal direction" refers to the elongated direction or lengthwise direction of the crate assembly (i.e., in the +/- X-direction of the coordinate axes depicted in the figures). The term "lateral direction" refers to the cross-wise direction of the crate assembly (i.e., in the +/- Y-direction of the coordinate axes depicted in the figures), and is transverse to the longitudinal direction. The term "vertical direction" refers to the upward-downward direction of the crate assembly (i.e., in the +/- Z-direction of the coordinate axes depicted in the figures).

[0044] Referring to FIG. 1, a crate assembly 10 includes an external crate assembly

12 and an internal spool support assembly 14 located within the external crate assembly 12. The external crate assembly 12 and internal spool support assembly 14 together form an upper crate assembly 15 and a lower crate assembly 17. The external crate assembly 12 includes a top 16, a bottom 18, and sides 20, 21 and ends 22, 23 that extend between the top 16 and the bottom 18. Located on the top 16 of the external crate assembly are guide members 24. The guide members 24 include a lengthwise extending portion 26 that extends in the longitudinal direction and a widthwise extending portion 28 that extends in the lateral direction across a gap 30 between the lengthwise extending portions 26 and the sides 20 and 21. The guide members 24 and resulting gaps 30 can facilitate stacking and securing crate assemblies 10, one on top of another for bulk shipping of the crate assemblies 10, for example, within a cargo container. Crate assemblies 10 may be shipped in stacks from one to eight crates high.

[0045] The bottom 18 includes support members 32 upon which the bottom 18 can rest elevated from the ground or floor. Spaces 34 between adjacent ones of the support member 32 can be sized to allow forks of a forklift to be inserted therein for a lifting and transport operation. The support members 32 extend lengthwise along the bottom 18 in the longitudinal direction. Widths of the support members 32 in the transverse direction are sized to be received by the gaps 30 between the lengthwise extending portions 26 and the sides 20 and 22 to facilitate stacking of the crate assemblies 10. [0046] The external crate assembly 12 includes the ends 22 and 23. The ends 22 and

23 each include a lower outer wall member 36 connected to the bottom 18 and an upper outer wall member 38 connected to the top 16 (only end 22 can be seen). The lower outer wall member 36 includes a spool-core receiving notch 46 sized to receive a spool core end. In some embodiments, the spool-core receiving notch 46 has an open side 48 closed by a bottom ledge 50 of the upper outer wall member 38. The upper outer wall member 38 may include handles 52 (e.g., openings) that can facilitate manual removal of the upper crate assembly 15 from the lower crate assembly 17, e.g., to access the spool of ultra-thin glass located therein.

[0047] Referring to FIG. 2, the crate assembly 10 is illustrated with the top 16 and side 20 removed to show the internal spool support assembly 14 within the volume 40. The internal spool support assembly 14 includes a lower spool support structure 54 and an upper spool support structure 56. The lower spool support structure 54 includes a first lower spool support assembly 58 located at the end 22 and a second lower spool support assembly 60 located at the opposite end 23 of the external crate assembly 12. The first and second lower spool support assemblies 58 and 60 are spaced-apart from one another and disconnected such that they can move relative to one another during use. The first lower spool support assembly 58 includes vertically arranged, side-by-side support members 62 and 64 that together form an end support structure 65 for supporting a spool core end of a spool of ultra-thin glass. The support members 62 and 64 are illustrated as being substantially planar board-like structures and extend widthwise in the lateral direction between the sides 20 and 21 of the external crate assembly 12. It should be noted that while two support members 62 and 64 are illustrated, there may be more or less than two support members, depending on the size and weight of the spool of ultra-thin glass to be transported. Each support member 62 and 64 includes a spool- core receiving notch 69 (FIG. 1) that aligns with the spool-core receiving notch 46 of the lower outer wall member 36.

[0048] Similarly, the second lower spool support assembly 60 includes vertically arranged, side-by-side support members 66 and 68 that together form an end support structure 71 for supporting the spool core end of the spool of ultra -thin glass. The support members 66 and 68 are illustrated as being substantially planar board-like structures and extend widthwise in the lateral direction between the sides 20 and 21 of the external crate assembly 12. As above, while two support members 66 and 68 are illustrated, there may be more or less than two support members, depending on the size and weight of the spool of ultra-thin glass to be transported. Each support member 66 and 68 includes a spool-core receiving notch 70 that aligns with a spool-core receiving notch 72 of lower outer wall member 75. The spool-core receiving notches 70 also align with the spool-core receiving notches 69 so that a central axis of the spool of the ultra-thin glass is substantially perpendicular to the ends 22 and 23 of the external crate assembly 12 when supported by the first and second lower spool support assemblies 58 and 60.

[0049] The first lower spool support assembly 58 is separated from the bottom 18 using a bottom isolation pad 76. The bottom isolation pad 76 may be a single isolation pad that extends a majority or substantially all of a width of the support members 62 and 64. The bottom isolation pad 76 may also extend across the entire thickness of both support members 62 and 64 to support the support members 62 and 64 spaced-from the bottom 18. In some embodiments, multiple bottom isolation pads may be used. The number and dimension of the bottom isolation pad 76 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0050] The first lower spool support assembly 58 may further be separated from the side 20 using side isolation pads 78 and 80. The side isolation pads 78 and 80 may extend along only portions of the heights of the support members 62 and 64. The side isolation pads 78 and 80 may also extend across the entire thickness of both support members 62 and 64 to support the support members 62 and 64 spaced-from the side 20. In some embodiments, a single side isolation pad may be used that extends along all or only some of the height of the support members 62 and 64. The number and dimension of the side isolation pads 78 and 80 may be selected depending on the size and dimension of, for example, the spool of the ultra- thin glass.

[0051] Referring to FIG. 3 illustrating the crate assembly 10 with the lower outer wall member 36 and the upper outer wall member 38 removed, the first lower spool assembly 58 may also be separated from the end 22 using end isolation pads 82, 84, 86 and 88. The end isolation pads 82, 84, 86 and 88 may extend along a height of the support members 62 and 64 and be sandwiched between the support member 64 and the lower outer wall member 36 (FIG. 1). As can be seen, the end isolation pads 82, 84, 86 and 88 extend vertically along a height of the support member 64. Multiple end isolation pads 82, 84, 86 and 88 are provided that are each spaced from one another in the widthwise direction. While the end isolation pads 82, 84, 86 and 88 are illustrated as being elongated in the vertical direction, they may be elongated in the widthwise direction. For example, as an alternative to being spaced-apart in the widthwise direction, the end isolation pads may extend laterally and be spaced-apart in the vertical direction. The number and dimension of the end isolation pads 82, 84, 86 and 88 may be selected depending on the size and dimension of, for example, the spool of the ultra- thin glass.

[0052] Referring still to FIG. 3, the first lower spool support assembly 58 may further be separated from the side 21 using side isolation pads 90 and 92. The side isolation pads 90 and 92 may extend along only portions of the heights of the support members 62 and 64. The side isolation pads 90 and 92 may also extend across the entire thickness of both support members 62 and 64 to support the support members 62 and 64 spaced-from the side 21. In some embodiments, a single side isolation pad may be used that extends along all or only some of the height of the support members 62 and 64. The number and dimension of the side isolation pads 90 and 92 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass. As can be appreciated, the side isolation pads 78, 80, 90 and 92 isolate the first lower spool support assembly 58 from opposite sides 20 and 21, the end isolation pads 82, 84, 86 and 88 isolate the first lower spool support assembly 58 from the end 22 and the bottom isolation pad 76 isolates the first lower spool support assembly 58 from the bottom 18.

[0053] Referring again to FIG. 2, the second lower spool support assembly 60 is separated from the bottom 18 using a bottom isolation pad 106. The bottom isolation pad 106 may be a single isolation pad that extends a majority or substantially all of a width of the support members 66 and 68. The bottom isolation pad 106 may also extend across the entire thickness of both support members 66 and 68 to support the support members 66 and 68 spaced-from the bottom 18. In some embodiments, multiple bottom isolation pads may be used. The number and dimension of the bottom isolation pad 106 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0054] The second lower spool support assembly 60 may further be separated from the side 20 using side isolation pads 108 and 110. The side isolation pads 108 and 110 may extend along only portions of the heights of the support members 66 and 68. The side isolation pads 78 and 80 may also extend across the entire thickness of both support members 66 and 68 to support the support members 66 and 68 spaced-from the side 20. In some embodiments, a single side isolation pad may be used that extends along all or only some of the height of the support members 66 and 68. The number and dimension of the side isolation pads 78 and 80 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0055] Referring to FIG. 4, illustrating the crate assembly 10 with the lower outer wall member 75 and the upper outer wall member 77 removed (FIG. 2), the second lower spool assembly 60 may also be separated from the end 23 using end isolation pads 112, 114, 116 and 118. The end isolation pads 112, 114, 116 and 118 may extend along a height of the support members 66 and 68 and be sandwiched between the support member 68 and the lower outer wall member 75. As can be seen, the end isolation pads 112, 114, 116 and 118 extend vertically along a height of the support member 68. Multiple end isolation pads 112, 114, 116 and 118 are provided that are each spaced from one another in the widthwise direction. While the end isolation pads 112, 114, 116 and 118 are illustrated as being elongated in the vertical direction, they may be elongated in the widthwise direction. For example, as an alternative to being spaced-apart in the widthwise direction, the end isolation pads may extend laterally and be spaced-apart in the vertical direction. The number and dimension of the end isolation pads 112, 114, 116 and 118 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0056] Referring still to FIG. 4, the second lower spool support assembly 60 may further be separated from the side 21 using side isolation pads 120 and 122. The side isolation pads 120 and 122 may extend along only portions of the heights of the support members 66 and 68. The side isolation pads 120 and 122 may also extend across the entire thickness of both support members 66 and 68 to support the support members 66 and 68 spaced-from the side 21. In some embodiments, a single side isolation pad may be used that extends along all or only some of the height of the support members 66 and 68. The number and dimension of the side isolation pads 120 and 122 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass. As can be appreciated, the side isolation pads 108, 110, 120 and 122 isolate the second lower spool support assembly 60 from opposite sides 20 and 21, the end isolation pads 112, 114, 116 and 118 isolate the second lower spool support assembly 60 from the end 23 and the bottom isolation pad 106 isolates the second lower spool support assembly 60 from the bottom 18.

[0057] Referring again to FIG. 2, the internal spool support assembly 14 includes the upper spool support structure 56. The upper spool support structure 56 includes a first upper spool support assembly 126 located at the end 22 and a second upper spool support assembly 128 located at the opposite end 23 of the external crate assembly 12. The first and second upper spool support assemblies 126 and 128 are spaced-apart from one another and disconnected such that they can move relative to one another during use. The first upper spool support assembly 126 includes vertically arranged, side-by-side support members 130 and 132 that together form an end support structure 134 for supporting the spool core end of the spool of ultra-thin glass from above. The support members 130 and 132 are illustrated as being substantially planar and extending widthwise in the lateral direction between the sides 20 and 21 of the external crate assembly 12. It should be noted that while two support members 130 and 132 are illustrated, there may be more or less than two support members, depending on the size and weight of the spool of ultra-thin glass to be transported. Each support member 130 and 132 includes a lower edge 135 that engages the support members 62 and 64 of the first lower support assembly 58 thereby enclosing their respective spool-core receiving notches 69.

[0058] Similarly, the second upper spool support assembly 128 includes vertically arranged, side-by-side support members 136 and 138 that together form an end support structure 140 for supporting the spool core end of the spool of ultra-thin glass. The support members 136 and 138 are illustrated as being substantially planar and extend widthwise in the lateral direction between the sides 20 and 21 of the external crate assembly 12. As above, while two support members 136 and 138 are illustrated, there may be more or less than two support members, depending on the size and weight of the spool of ultra-thin glass to be transported. Each support member 136 and 138 includes a lower edge 141 that engages the support members 66 and 68 of the second lower support assembly 60 thereby enclosing their respective spool -core receiving notches 70.

[0059] The first upper spool support assembly 126 is separated from the top 16 using a top isolation pad 142. The top isolation pad 142 may be a single isolation pad that extends a majority or substantially all of a width of the support members 130 and 132. The top isolation pad 142 may also extend across the entire thickness of both support members 130 and 132 to support the support members 130 and 132 spaced-from the top 16. In some embodiments, multiple top isolation pads may be used. The number and dimension of the top isolation pad 142 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0060] Unlike the first lower spool support assembly 58, the first upper spool support assembly 126 may not include side isolation pads that separate the first upper spool support assembly 126 from the sides 20 and 21. In this example, side isolation pads are not necessary on the upper spool support assembly 126 because the first upper spool support assembly 126 provides relatively little or no lateral support for the spool of ultra-thin glass as the spool core rests squarely within the spool-core receiving notches 69 of the first lower spool support assembly 58. In other embodiments, however, such as where the first upper spool support assembly 126 includes a spool-core receiving notch, side isolation pads may be used to isolate the first upper spool support assembly 126 from the sides 20 and 21 of the external crate assembly 12.

[0061] Referring again to FIG. 3, the first upper spool support assembly 126 may also be separated from the end 22 using end isolation pads 156, 158, 160 and 162. The end isolation pads 156, 158, 160 and 162 may extend along a height of the support members 130 and 132 and be sandwiched between the support member 132 and the upper outer wall member 38 (FIG. 1). As can be seen, the end isolation pads 156, 158, 160 and 162 extend vertically along a height of the support member 132 and are aligned with the end isolation pads 82, 84, 86 and 88 thereby forming columns. In other embodiments, the end isolation pads may not be aligned. In alternative embodiments, the end isolation pads 156, 158, 160 and 162 may be formed as one-piece with and an extension of the corresponding end isolation pads 82, 84, 86, and 88. Multiple end isolation pads 156, 158, 160 and 162 are provided that are each spaced from one another in the widthwise direction. While the end isolation pads 156, 158, 160 and 162 are illustrated as being elongated in the vertical direction, they may be elongated in the widthwise direction. For example, as an alternative to being spaced-apart in the widthwise direction, the end isolation pads may extend laterally and be spaced-apart in the vertical direction. The number and dimension of the end isolation pads 156, 158, 160 and 162 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass. As can be appreciated, the end isolation pads 156, 158, 160 and 162 isolate the first upper spool support assembly 126 from the end 22 and the top isolation pad 142 isolates the first upper spool support assembly 126 from the top 16.

[0062] Referring again to FIG. 2, the second upper spool support assembly 128 is separated from the top 16 using a top isolation pad 166. The top isolation pad 166 may be a single isolation pad that extends a majority or substantially all of a width of the support members 136 and 138. The top isolation pad 166 may also extend across the entire thickness of both support members 136 and 138 to support the support members 136 and 138 spaced- from the top 16. In some embodiments, multiple top isolation pads may be used. The number and dimension of the top isolation pad 166 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass.

[0063] Unlike the second lower spool support assembly 60, the second upper spool support assembly 128 may not include side isolation pads that separate the second upper spool support assembly 128 from the sides 20 and 21. As noted above regarding the upper spool supporting assembly 126, side isolation pads are not necessary on upper spool supporting assembly 128 because the second upper spool support assembly 128 provides relatively little or no lateral support for the spool of ultra-thin glass as the spool core rests squarely within the spool-core receiving notches 70 of the second lower spool support assembly 60. In other embodiments, however, such as where the second upper spool support assembly 128 includes a spool-core receiving notch, side isolation pads may be used to isolate the second upper spool support assembly 128 from the sides 20 and 21 of the external crate assembly 12.

[0064] Referring again to FIG. 4, the second upper spool support assembly 128 may also be separated from the end 23 using end isolation pads 170, 172, 174 and 176. The end isolation pads 170, 172, 174 and 176 may extend along a height of the support members 136 and 138 and be sandwiched between the support member 138 and the upper outer wall member 77. As can be seen, the end isolation pads 170, 172, 174 and 176 extend vertically along a height of the support member 138 and are aligned with the end isolation pads 112, 114, 116 and 118 thereby forming columns. In other embodiments, the end isolation pads may not be aligned. In some embodiments, the end isolation pads 170, 172, 174 and 176 may be formed as one-piece with and an extension of the corresponding end isolation pads 112, 114, 116 and 118. Multiple end isolation pads 170, 172, 174 and 176 are provided that are each spaced from one another in the widthwise direction. While the end isolation pads 170, 172, 174 and 176 are illustrated as being elongated in the vertical direction, they may be elongated in the widthwise direction. For example, as an alternative to being spaced-apart in the widthwise direction, the end isolation pads may extend laterally and be spaced-apart in the vertical direction. The number and dimension of the end isolation pads 170, 172, 174 and 176 may be selected depending on the size and dimension of, for example, the spool of the ultra-thin glass. As can be appreciated, the end isolation pads 170, 172, 174 and 176 isolate the second upper spool support assembly 128 from the end 23 and the top isolation pad 166 isolates the second upper spool support assembly 128 from the top 16.

[0065] Referring to FIG. 5, the crate assembly 10 is illustrated including the external crate assembly 12 and the internal spool support assembly 14. A spool 200 of ultra-thin glass is supported by the internal spool support assembly 14. The spool 200 of ultra-thin glass may weigh from about 181 kg (400 pounds) to about 362 kg (800 pounds), such as about 227 kg weight (500 pounds) or more, such as about 272 kg (600 pounds). The spool 200 includes a spool core 202 and spool flanges 204 and 206 that are located at opposite ends 208 and 210 of the wound, ultra-thin glass 212. Spool core ends 214 and 216 protrude outwardly beyond the spool flanges 204 and 206. The spool core end 214 is received by the spool-core receiving notches 69 of the first lower spool support assembly 58 and spool core end 216 is received by the spool-core receiving notches 70 of the second lower spool support assembly 60. In some embodiments, spool flanges 204, 206, need not be present.

[0066] As can be seen, even with the weight of the spool 200 present, the bottom isolation pads 76 and 106 can maintain separation of the first and second lower spool support assemblies 58 and 60 from the bottom 16 of the external crate assembly 12. The isolation pads may be formed of a material of suitable density to absorb the vibration, shock, and acceleration of the spool. In certain embodiments, this material may be from about 0.254 cm to about 12.7 cm (0.1 inch to 5 inches) thick. In other embodiments, the material may be from about 0.5 cm to about 10.2 cm (0.2 inch to 4 inches) thick. In still other embodiments, this material may be from about 0.76 cm to about 7.6 cm (0.3 inch to 3 inches) thick. In yet further embodiments, this material may be from about 2 cm to about 5 cm (0.8 to 2 inches) thick depending on the location of the material in the crate. The material in certain embodiments may comprise a polyethylene foam, such as commercially available as DOW Ethafoam HS 900 and the like.

[0067] Tests standardized by the International Safe Transit Association ("ISTA")

Procedure 3B may be used to test the forces acting on the crate assembly. Procedure 3B is a general simulation test for packaged-products shipped through a motor carrier (truck) delivery system, where different types of packaged-products, often from different shippers and intended for different ultimate destinations, are mixed in the same load. This type of shipment is called LTL (less-than-truckload).

[0068] To assemble various embodiments, a manufacturer may start with the bottom.

The bottom may be a thin, substantially flat board selected to support the external crate assembly, the upper and lower spool support structures and the bulk spool. The bottom may be made from wood, plastic, metal, or the like. Structure may be added to the bottom to form slots for the insertion of a fork lift's forks and to make the external crate assembly stackable. These slots may make transfer and carrying of the crates via forklift or other suitable carrier more efficient. Certain embodiments of the crate assembly may ship in containers in which they are stacked from one to eight crates high.

[0069] Attached to the bottom may be the remaining external crate assembly including four substantially planar sides that may make up the walls extending between the top and bottom pieces of the external crate assembly. These sides may be arranged such that they form a rectangular shaped box, each side being substantially orthogonal to the other sides on either side of it. These sides may be made of wood, plastic, metal, or any other suitable material. These sides may be attached via nails, screws, bolts, brackets, or some other suitable methods, or may be attached via an epoxy. Some of the sides may be split into two sections, an upper and a lower, that are removably coupled to one another, such that the top part of the side may be permanently connected to the external assembly top and the bottom part of the side may be permanently connected to the bottom of the external crate assembly. The sides may contain handles, slots, or some other suitable means to make the handling of the walls easier and more convenient for the users of the crate assembly. Two opposite sides may have a spool-core receiving notch extending therethrough, this spool -core receiving notch designed such that the notch cradles a spool core end of the spool and inhibits movement of the spool during transport.

[0070] To assemble the isolation pads, the isolation pads may be adhered or otherwise connected to the external crate assembly at the various locations discussed above. The top section may be constructed in a fashion similar to the bottom section, starting with a substantially flat piece of wood, plastic, metal, or the like and adding two or four sides, each substantially orthogonal to the sides surrounding it. The sides may include pre-fabricated handles in the form of voids, or may be external to the wall structure in such form as a handle, rope, or the like. These handles may be added to the walls of the top piece of the external crate assembly after the top piece has been removably connected with the bottom piece or before. Once the top section is constructed, isolation pads may be placed within the top section as described above. The upper and lower support structures may then be assembled to their respective top and bottom sections.

[0071] The ultra-thin flexible glass may have a thickness of about 0.3 mm or less including but not limited to thicknesses of, for example, about 0.01 -0.05 mm, about 0.05-0.1 mm, about 0.1-0.15 mm, about 0.15-0.3 mm, about .100 to about .200 mm, 0.3, 0.275, 0.25, 0.225, 0.2, 0.19, 0.18, 0.17, 0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.10, 0.09, 0.08 0.07, 0.06, 0.05, 0.04, 0.03, 0.02, or 0.01 mm. The ultra-thin glass may be formed of glass, a glass ceramic, a ceramic material or composites thereof. A fusion process (e.g., downdraw process) that forms high quality flexible glass can be used in a variety of devices and one such application is flat panel displays. Glass produced in a fusion process has surfaces with superior flatness and smoothness when compared to glass produced by other methods. The fusion process is described in U.S. Patent Serial Nos. 3,338,696 and 3,682,609. Other suitable glass forming methods include a float process, updraw, down draw, press rolling, and slot draw methods. Additionally, the flexible glass may also contain anti-microbial properties by using a chemical composition for the glass including an Ag ion concentration on the surface in the range greater than 0 to 0.047 μg/cm ² , further described in U.S. Patent Application Publication No. 2012/0034435 Al . The flexible glass may also be coated with a glaze composed of silver, or otherwise doped with silver ions, to gain the desired antimicrobial properties, as further described in U.S. Patent Application Publication No. 2011/0081542 Al . Additionally, the flexible glass may have a molar composition of 50% SiC"2, 25%) CaO, and 25% Na ₂ 0 to achieve the desired anti-microbial effects.

[0072] The terms "substantial," "substantially," and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a "substantially planar" surface is intended to denote a surface that is planar or approximately planar. Moreover, "substantially" is intended to denote that two values are equal or approximately equal. In some embodiments, "substantially" may denote values within about 10%> of each other, such as within about 5% of each other, or within about 2% of each other.

[0073] While particular embodiments have been illustrated and described herein, it should be understood that various other changes and modifications may be made without departing from the spirit and scope of the claimed subject matter. Moreover, although various embodiments of the claimed subject matter have been described herein, such embodiments need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of the claimed subject matter.