DAMAGE RESISTANT CONTAINER AND SLEEVE PACK ASSEMBLY

Field of the Invention

The present invention relates generally to reusable

containers for suspending pouches of product within and more

specifically to an improved, damage-resistant sleeve pack assembly

having a collapsible design for better withstanding denting,

puncturing and general abuse.

Background of the Invention

Relatively large reusable containers are utilized by

manufacturers to ship a variety of different products to their

customers. For example, in the automobile industry, a plant

assembling a particular automobile might utilize a number of

different parts manufacturers. These manufacturers ship their

respective parts to the plant in reusable containers where the parts

are then assembled together into a finished automobile. The

reusable containers are often returned to the parts manufacturers for use in further shipments, thus saving the manufacturers cost of

the containers.

The construction of some such shipping containers

includes a pallet base, a cover and a rectangular sleeve pack which is situated between the base and cover to form the sidewalls and

body of the container. Such a design provides a versatile and

lightweight shipping container which may be reused time and

again. While some products are simply placed in the containers on

the base and against the sidewalls, many products shipped in such

containers are more susceptible to being damaged during shipment. Therefore, some available container sleeve pack designs utilize

hanging pouches which contain the product and suspend it away

from the base or sidewalls of the container. The pouches are flat

and usually formed of cloth and are suspended along a top edge

thereof by rigid support bars or other structures extending from one

side of the container to the other inside the sleeve pack. The

successive pouches are arranged in side-by-side fashion and the

rigid bars extend generally parallel with each other across the

sleeve pack.

When reusable containers are moved, such as during

loading and unloading, they are often abused, such as by being

crushed or smashed by the forks of a forklift or by some other

lifting or moving device. The sleeve pack sidewalls are often

punctured or severely dented, making the container unfit for re-use.

The container sleeve pack is then either thrown away and replaced

or bent back into shape, if possible. Both altematives are costly

and wasteful of time and resources.

Traditionally, the construction of container, and particularly sleeve packs, has been made heavier and more rigid to

withstand the abusive forces to which the containers are exposed.

For example, the sleeve pack sidewalls are made of thicker, more

durable material. Furthermore, the edges and corners along the

top, bottom and sides of the sleeve pack are reinforced, such as

with metal. In sleeve packs utilizing product pouches, the rigid

support bars provide rigidity to the sleeve pack when an impact

force occurs at a side to which the bars are anchored. However,

despite efforts at reinforcement container sleeve packs are still

punctured and dented by heavy machines and thus rendered unusable.

Recently, and against convention, some containers

and sleeve packs are being designed with a lighter construction

which gives way when the container is abused. For example, the

sidewalls of the sleeve pack yield inwardly when a forklift or other

machine smashes into the container side. Similarly, the sides will

yield outwardly to weight and forces from within. The sidewalls

are constructed of a resilient material which returns to its original

shape when the force is removed. Since the sidewalls have give,

they are less likely to be punctured, and dents may easily be

pushed out or are totally eliminated. While resilient sidewalls have

eliminated some denting and puncturing, other rigid structures within the sleeve pack still tend to prevent sidewall flexing making

the sleeve pack susceptible to permanent damage. Particularly, the rigid bars supporting and suspending the product pouches work

against the give of the resilient sidewalls. If the damaging force is

strong enough, the unyielding sidewalls are punctured or the bars

bend and prevent the sidewalls from returning to their original

shape.

Another problem encountered when using reusable

sleeve packs is the wear on the edges of the sleeve pack which

contact the base and cover. The top and bottom edges are the

same resilient materials as the sidewalls and are susceptible to

being dented, smashed or otherwise damaged. In sleeve packs

using hanging pouches, the top edge is particularly susceptible to

being damaged because it must support the weight of the hanging

products.

Accordingly, it is an objective of the present invention

to provide a reusable container which is more durable and less

susceptible to being permanently damaged by abusive handling

during use. It is further an objective to prevent permanent damage to containers using sieeve packs which suspend pouches of

product within the sleeve pack. It is another objective to protect

the delicate edges of the sleeve pack without adding to the overall

weight and complexity of the container. It is still another objective to provide a lightweight yet durable sleeve pack and container

which is able to withstand the rigors of use.

Summary of the Invention

The present invention addresses the above-stated

objectives by providing a sleeve pack and container for storing and

shipping products which is damage resistant and better able to

withstand the abusive forces encountered when being moved and

handled. To that end, the sleeve pack comprises a body having a

top, a bottom and opposing rectangular sidewalls. The sleeve pack

body is formed generally in the shape of a rectangle for placement

between a base and a cover to form a reusable container. The

sidewalls of the body are preferably formed of a single or double

layer of plastic corrugated material which is generally flexible to

provide a certain amount of give under a force which is applied

thereto, such as by a forklift being driven into the sidewall of the

sleeve pack. The resilient sidewalls will generally return to their

original shape when smashed in or dented, and the give of the

sidewalls reduces and prevents puncturing of the sleeve pack.

A plurality of telescoping support bars are positioned

in the sieeve pack body and span between two opposing sidewalls.

The bars are slidably fixed to the sidewalls proximate the top edge

of the sleeve pack. Fabric pouches hang from the support bars and

contain the shipped products to suspend the products from the

bars. The products are thus suspended above the base and away

from the sidewalls of the container. Each telescoping support bar

is operable to telescope to a variety of lengths when a force is

applied to the end of the bar. The telescoping support bar in

combination with the resilient sidewalls provides a container sleeve

pack which absorbs damaging forces to prevent permanent

damage. That is, when a force outside the container is applied to

one of the sidewalls between which the support bar spans, the

sidewall flexes inwardly and temporarily shortens the length of the

support bar. Similarly, any forces from within the container cause

the sidewalls to flex outwardly and increase the effective length of

the bar. In that way, and in accordance with the principles of the

present invention, pouches of product are suspended within the

container and the bars supporting the pouches do not hinder the

flexibility and damage resistance of the sieeve pack. In an embodiment of the invention, the telescoping support bar is biased to telescope and return to an extended length

when an inwardly directed force on the sidewalls is removed and

the sidewalls retum to their original shapes. Altematively, the

support bar might simply telescope back to an extended length under the force of the resilient sidewalls returning to their original

shape. In still another embodiment, the bias of the bar retums the

telescopically elongated bar to its original shortened position

whenever a force directed outwardly of the sleeve pack is removed.

Each end of a support bar is held by an elongated

channel extending along the length of a sidewall. The ends of the

support bars slidably move within the channels so that the

positions of the bars may be adjusted along the sleeve pack

sidewall, such as to access a particular product pouch. Each

channel is connected to an elongated mounting structure which

engages the top edge of the sleeve pack sidewall to suspend the

channel and the support bars proximate the top of the sleeve pack.

The sidewalls suspending the support bar are single layered or may

be folded over to create double-wall portions along the top edge.

One embodiment of the mounting structure includes a

flange connected to the bar channel. The flange is riveted or

bolted to the side wall for securement. Another embodiment of the

mounting structure includes a hook section which is connected to

the bar channel. The hook section hooks over the sidewall top

edge and a rivet or bolt extends through the hook section and

sidewall for securement.

Another embodiment of the mounting structure

includes a hook section and a ridge spaced from the hook section.

The hook section hooks over the sidewall top edge and the ridge

engages an edge of a double-wall portion which is spaced below

the top edge of the sidewall. The bar track is positioned generally

between the hook section and ridge, close to the ridge. The hook

section and ridge cooperate to thoroughly secure the track to the

sidewall. Still another embodiment has opposing flanges on either

side of the channel which fit into a slot formed in one of the walls

of the double-wall portion.

The mounting structures of the invention utilizing the hook sections function as elongated protective edge rails for the

sleeve pack. The edge rail is preferably metal and covers the top

edge of the sleeve pack to structurally strengthen the top edge and

protect the edge from damage. An alternative embodiment of the edge rail is utilized with sleeve packs which do not support pouches and thus does not include the channel for suspending the

support bars. One edge rail of the invention is riveted or bolted for

securement and other embodiments are snapped onto a double-wall portion without additional fastening structures.

In one embodiment of the invention, the telescoping

support bar comprises a cylindrical exterior tube and two opposing

cylindrical rods which fit into the opposite ends of the exterior

tube. The opposing rods telescope inside the tube to vary the

length of the bar as necessary to adapt to forces applied to the sidewalls. Preferably, the rods slide freely in the tube.

Alterntaively, a compression spring may be positioned between the

rods to bias the rods away from each other when the bar is

compressed such that the support bar is loaded to extend to its

original length when the compressing force is removed. In another

altemative embodiment, the two inward ends of the rods may be

attached to the spring to also bias the bar to a shortened position

whenever forces inside the sleeve pack extend the bar. Caps on

the ends of the bars secure them within the channels of the

mounting structures.

Thereby, the damage resistant sleeve pack of the

present invention provides a reusable container which is more

durable and less susceptible to being permanently damaged by abusive handling during use. The telescoping support bar

telescopes in length when force is applied to the sidewalls and

prevents permanent denting of the sleeve pack sidewalls and

internal structures. Thereby, pouches of product may be

suspended within the sleeve pack without detrimentally affecting

its damage resistance and without jeopardizing its reusability. The

present invention provides a lightweight sleeve pack with enhanced

edge protection which is resilient and less prone to being damaged

along its edges.

The above and other objects and advantages of the

present invention shall be made apparent from the accompanying

drawings and the detailed description thereof.

Brief Description of the Drawings

The accompanying drawings, which are incorporated

in and constitute a part of this specification, illustrate embodiments

of the invention and, together with a general description of the

invention given above, and the detailed description of the

embodiments given below, serve to explain the principles of the invention.

Fig. 1 is a perspective view of the container sleeve

pack of the present invention utilizing the telescoping support bar

and product pouches;

Fig. 2 is a cross-sectional view along lines 2-2 of Fig. 1 illustrating the extensible support bar;

Fig. 3 is a cross-sectional view similar to Fig. 2 illustrating indentation of the sieeve pack sidewalls and telescoping of the extensible support bar;

Fig. 4 is a cross-sectional view of an edge rail of the

present invention along an edge of the sleeve pack;

Fig. 5 is a cross-sectional view of an alternative

embodiment of a mounting structure of the invention;

Fig. 6 is a cross-sectional view of an alternative

embodiment of a mounting structure of the invention; and

Fig. 7 is a cross-sectional view of an altemative

embodiment of a mounting structure of the invention.

Detailed Description of Specific Embodiments

Fig. 1 illustrates the reusable, damage-resistant

container 10 and sleeve pack assembly 1 2 of the present invention.

Container 10 incorporates sleeve pack assembly 1 2, and the

bottom 1 3 of the sleeve pack rests upon a base or pallet 14.

Container 10 also includes a cover (not shown) which is generally

similar to base 14 and seals the top 1 5 of the sleeve pack 12.

Container 1 0 is used to ship and store products for use in

manufacturing.

Sleeve pack 1 2 comprises four generally rectangular

sidewalls 1 6 which may be joined together by corner structures 1 8

into a sieeve pack structure having a box-like shape. A plurality of

support bars 20 (see Figs. 2 and 3) extend between two opposing

sidewalls 1 6 of the sleeve pack 1 2. Fabric pouches 22 hang from

the support bars 20 and contain product. The product is

suspended above the base 1 4 and away from the sidewalls 1 6 of

the sleeve pack 1 2. In a preferred embodiment, the pouches are all

connected together accordion-style and each pouch has two walls

23 and a bottom (not shown), with adjacent pouches sharing a

common wall. Each pouch wall 23 has a fold-over portion 24

which wraps around a support bar 20; therefore, each wall is

supported by a bar 20. Access to the pouches 22 is provided

between the walls proximate the fold-over portion 24 to allow

access to the product from at the top edge 26 of sleeve pack 1 2.

The support bars 20 are suspended by mounting structures 28

which are secured to the opposing sidewalls 1 6 proximate the top

edge 26 thereof.

The sidewalls 1 6 of sleeve pack 1 2 are preferably

made of a single sheet of plastic corrugated material which is

flexible and resilient. Preferably, a single sheet of 10mm thick material is used, although two sheets of back-to-back 5mm

material might also be used. The sidewalls 1 6 thereby have an

amount of inward or outward give when force is applied thereto.

Referring to Fig. 3, for example, when an inward smashing or

crushing force (illustrated by arrows 30) is applied to sidewalls 16,

such as by a forklift fork (not shown), the sidewall 1 6 flexes

inwardly. Upon removal of the force, the flexible plastic corrugated

material would generally retum to its original shape. Therefore, the

sleeve pack 1 2 may be temporarily dented, but the dents tend to

pop back out as the side wall returns to its original shape to

provide a reusable sleeve pack. Additionally, the give of the

resilient sidewalls 1 6 reduces and resists puncturing of the

sidewalls.

Altematively, the sidewalls 1 6 may be formed of paper

corrugated material which is flexible and resilient, although, plastic

corrugated materials tends to be more durable and moisture

resistant.

Referring now to Fig. 2, one embodiment of the sleeve

pack 1 2 of the invention includes sidewalls 16 which are folded over at their upper ends to provide a double-wall portion 34 along

the top edge 26 of the sleeve pack and sidewall 1 6. The sidewall

material may also be a thick, single-wall material, e.g., 1 0mm

thickness, which is preferable and is illustrated in Figs. 6 and 7.

When the material is thinner, e.g., 5mm thickness, the double-wall

portion 34 enhances the strength of the top edge 26 of the sleeve

pack 1 2 and provides structural strength and support for the

container cover (not shown). The elongated mounting structure 28

illustrated in Figs. 2 and 3 is preferably formed of metal and

comprises a curved hook section 36 which hooks over both sides

of the double-wall portion 34. A 1 80° curve portion 37 of the

hook section engages and covers the top edge 26. An outwardly

extending ridge 38 is formed at the lower end of the mounting

structure 28 and extends in the outward direction of hook section

36. When the hook section 36, and particularly curve portion 37,

is placed over the top edge 26 of the sidewall 1 6, the ridge 38

engages a lower edge 40 of the double-wall portion 34 to secure mounting structure 28. Ridge 38 is spaced below hook section 36 and holds the curve portion 37 securely over the double-wall

portion 34. The distance between the curve portion 37 and ridge

38 is preferably generally equal to the distance between edge 26

and egde 40 for a snug fit. The unique hook section 36 and ridge

38 make the mounting structure effectively snap into place when assembled without the need for extemal fasteners or other securing

devices. The 1 80° curve portion 37 is illustrated as two 90°

bends; however, a smother curve portion might also be utlized.

The mounting structure 28 further comprises a channel 42 which receives and supports the ends of the

telescoping support bar 20. In the embodiment of the invention

illustrated in Fig. 2, the channel has a C-shaped cross section and

engages the support bar ends from above and below.

Alternatively, the channel 42 may have an F-shaped cross-section

or a J-shaped cross-section which engages the ends of the support

bars 20 and suspends the bars in place.

The ends of the support bar 20 slide within the

channels 42 so that the support bars 20 and the pouches 24 may

be easily moved in the sleeve pack, such as to access products.

The adjustable length of the telescoping support bar 20 provides

smooth and easy movement of the bar 20 and prevents binding

between the bar and channel 42 which occurs with traditional rigid

support bars. Nut caps 44 are preferably placed at the ends of the

support bar 20 to hold the bar ends in place within the channels 42. The upper and lower legs 43 of the channel 42 confine the

flange 45 of cap 44 and thus confine the ends of bars 20. When

the sleeve pack is assembled, the ends of the support bar 20 are

slid into the channels 42 and the ends of the channels are capped

or otherwise modified and sealed to keep the support bars from

sliding out the ends of the channels 42. The unique shape of the

mounting structure 28 and its interaction with the bars 20 ensures

strong contact with the sieeve pack. The channel 42 is positioned

below the hook section 36 and adjacent ridge 38. Therefore, the

weight of the bars 20 and suspended pouches 22 pivot the

structure 28 proximate hook section 36 and forces ridge 38 against

edge 40. In the embodiment of the telescoping support bar 20

illustrated in the drawings, the bar comprises an exterior cylindrical

tube 46 which is formed of a metal such as aluminum or some

other suitable material. For example, the exterior tube 46 might

also be made of fiberglass or PVC plastic. Bar 20 includes two telescoping rods 48, each one positioned inside of an end of tube

46. The rods are preferably solid but may also be smaller diameter

tubes. The opposing rods 48 smoothly and freely telescope within

tube 46 to vary the length of the support bar 20 in accordance

with the principles of the present invention.

Preferably, no biasing structure is utilized in the bar 20

and the rods 48 would simply be pushed in and pulled outwardly

by channels 42 acting on the rod ends and caps 44 when the

resilient sidewalls 1 6 return to their original position after being

inwardly or outwardly dented. Without a biasing structure, the

length of the support bar 20 is controlled exclusively by the

movement of the sidewalls 1 6.

Alternatively, support bar 20 may include a biasing

structure to return the bar to a desired length when it has been

compressed or extended. For example, a compression spring 50,

shown in phantom in Figs. 2 and 3, may be placed inside of

exterior tube 46 between the inner ends 47 of rods 48. The inner

ends 47 of the rods 48 would engage spring 50, and compress the

spring when the support bar 20 is compressed, such as by an

inward force 30 on the sidewalls 1 6 (see Fig. 3) . When the force

is removed, the spring 50 would act on the rods 48 to telescope

them outwardly in length so that the bar 20 returns to its original

length and the sidewall 1 6 retums to its original shape. Another

biasing structure might be utilized instead of a spring. For

example, a compressible cylinder (not shown) might be utilized

between rods 48. Fig. 3 illustrates operation of the present invention

during the application of force to a sidewall 1 6. For example,

when an inward force is applied, as illustrated by arrows 30,

sidewall 1 6 is dented inwardly moving channel 42a inwardly also.

As may be seen on the left side of Fig. 3, the channel 42a engages

the cap 44 and the end of rod 48a driving the rod 48a inwardly

into the respective end of exterior tube 46. The opposite rod 48b

is held in place by the respective channel 42b, and the driven rod

48a moves in tube 46 so that the support bar is shortened in its

effective length. Thus, minimal outward resistance is provided by

telescoping support bar 20 when sidewall 1 6 is dented or

otherwise forced inwardly. The telescoping support bar absorbs

the force and does not detrimentally affect the resiliency and

flexibility of the sleeve pack sidewalls 1 6. Upon removal of the

inward forces 30, the resilient sidewall 1 6 will retum to its original

shape and the rod 48 will be pulled outwardly of exterior tube 46 by the movement of channel 42 to retum the support bar 20 to its original length. Since the support bars 20 telescope, the resilient give of the sidewall 1 6 is not jeopardized, and thus puncturing of

the sidewalls is less likely to occur. Furthermore, telescoping

support bar 20 does not hinder the sidewalls 1 6 from returning to

their original shape. Traditional rigid support bars would resist

force 30 and the deformation of sidewall 1 6 and would thus

increase the incidence of the puncturing of the sidewall. In the

past, if the force 30 was not sufficient to puncture sidewall 16, but

was strong enough to overcome the rigidity of the ridge support

bar, the support bar would bend and thereby hold the deformed or

dented sidewall 1 6 in a permanently deformed state. The support

bar would then have to be bent back into its extended length so

that the sieeve pack was again reusable. As may be appreciated,

such constant maintenance of sleeve packs is expensive and

impractical. If a compression spring 50 or other biasing structure is

utilized, inward movement of the rods 48 would compress the

structure 50 and the rods 48 would be biased to retum to their

original position.

While the Figures illustrate an inward force 30 on the

sidewalls 1 6, an outward force from within the sleeve pack might

also occur. The resilient sidewalls 1 6 and the telescoping support

bar 20 would move as described above, except in an opposite

direction, and permanent damage to the sleeve pack 1 2 is avoided.

If a spring 50 is used, it may be unconnected from the ends 47 of the rods 48 and may only provide outward biasing. Alternatively,

the rod ends 47 may be coupled to the spring 50 to provide an

inward biasing of bar 20 when the sidewalls are pushed outwardly.

In accordance with another aspect of the present

invention, the mounting structure 28 functions as an elongated

protective edge rail for the sleeve pack 1 2. The hook section 36 of

mounting structure 28 hooks over the top edge 26 of the sidewall

1 6 which will coincide with the top edge of the double-wall portion

34 if a thin layer of sidewall material is used instead of a thick layer

as illustrated in Figs. 6 and 7. The hook section 36 covers the top

edge 26 and structurally strengthens the top edge to protect the

edge from damage which might be incurred during use of the

sleeve pack 1 2.

The unique shape of the one embodiment of the

mounting structure including the opposing hook section 36 and

ridge 38 provides a lightweight edge rail which may be fastened quickly and easily without extemal fasteners. Therefore, the

mounting structure 28 in Figs. 2 and 3 serves the dual function as an edge rail to protect and strengthen the top edge 26 of the

sleeve pack 1 2 and also as a mount to support the ends of support

bars 20 to suspend pouches within the sleeve pack.

The sleeve pack of the present invention is more

damage resistant than has traditionally been possible and thus the

overall container 1 0 may have a lighter and more inexpensive

construction. Furthermore, the pouches 24 may be easily moved

and manipulated within the sleeve pack for access to the products therein because the telescoping support bars 20 ensure smooth

movement within channels 42 without binding the ends of the

support bars.

Some sleeve packs are utilized without support bars

and pouches wherein product is simply placed in the sieeve pack to

rest on the base 14 and against the sidewalls 1 6. As illustrated in

Fig. 4, the unique hook section 36 and ridge 38 of the mounting

structure 28 might be utilized without channel 42 to strengthen the

top edge 26 of the sleeve pack 1 2. The double-wall portion 34 is

engaged by an edge rail structure 56 including a hook section 58 and an outwardly extending ridge 60. The hook section 58

includes a curve 59 which hooks over the top edge 26 of the sieeve pack 12 and double-wall portion 34 while the ridge 60

engages edge 40 of the double-wall portion 34. Therefore, the top edge 26 of the sieeve pack 1 2 is reinforced and structurally

strengthened in those sleeve packs which do not utilize pouches 24

and support bars 20 and thus do not require channels 42 to be

supported from the sidewalls. The edge rail structure 56 increases

the durability of the sleeve pack and provides a more solid

perimeter for engaging the cover (not shown) of the container 10.

Similarly, the edge rail structure 56 might be utilized along a

bottom edge of the sieeve pack for further increasing its durability

and providing a more stable perimeter for coupling to base 14.

Figs. 5, 6 and 7 illustrate alternative embodiments of

the mounting structure utilized to support the ends of the support

bars 20.

In Fig. 5, a slot 62 is formed on the inside wall 63 of a

double-wall portion 64. A mounting structure 66 includes a C-

shaped channel 68 to receive the support bar ends. Flanges 69 are

formed on either side of channel 68 and the mounting structure 66 is slid into slot 62. The weight of the bars 20 and pouches 22 hold the mounting structure 66 securely within the double-wall portion

64 with the flanges 69 between the inner wall 63 and outer wall

65 of the double-wall portion 64.

Another alternative embodiment of the mounting

structure is illustrated in Fig. 6 for use with a single wall sidewall

material 71 . Mounting structure 70 includes a C-shaped channel

72 and a flange 74 which projects upwardly from the channel 72.

The flange 74 lies against the sidewall 71 and a rivet or bolt 76

extends through the flange 74 and sidewall 71 to secure the

mounting structure 70 to the sidewall 71 .

A still further altemative embodiment is illustrated in

Fig. 7. Mounting structure 80 is somewhat similar to the mounting

structures 28 illustrated in Figs. 2 and 3. However, mounting

structure 80 is preferably used with the single wail sidewall 71 and

does not utilize a ridge 38 to engage an edge 40 of a double-wall

portion. Instead a rivet or other fastener 82 extends through the

sidewall 71 and through both sides of the hook section 84: The mounting structure 80 also functions as an edge rail to protect and

strengthen the top edge 83 of the sidewall 71 as discussed

hereinabove.

While each of the alternative embodiments illustrated in Figs. 5, 6 and 7 utilize C-shaped channels, it will be understood

by a person of ordinary skill in the art that other channels such as F-shaped channels or J-shaped channels might also be utilized to

support the ends of support bars 20.

While the present invention has been illustrated by a

description of various embodiments and while these embodiments

have been described in considerable detail, it is not the intention of

the applicants to restrict or in any way limit the scope of the

appended claims to such detail. Additional advantages and

modifications will readily appear to those of ordinary skill in the art.

The invention in its broader aspects is therefore not limited to the

specific details, representative apparatus and method, and

illustrative example shown and described. Accordingly, departures

may be made from such details without departing from the spirit or

scope of applicant's inventive concept.

What is claimed is: