Field of Invention

The present invention relates to the field of the transportation and storage of goods and to a transport and storage system and in particular, but not necessarily restricted thereto, a system for the transportation and storage of palletised goods.

Background to the Invention

In the field of logistics, that is the field of movement and supply of produce and materials, the transportation of intermediate and finished products is frequently assisted by the use of pallets. A pallet typically comprises a flat rectangular structure that supports goods in a stable fashion whether remaining in a transport vehicle - such as a lorry, container etc., a warehouse, storage area etc. or being lifted by a forklift, pallet truck, front loader, or other handling device. Pallets are commonly found in a wide range of industries and services, forming an essential part of many mechanical handling systems in factories, distribution warehouses and the like. Pallets are manufactured from a variety of materials, most commonly from : timber 10 per Figure la; plastics 11 per Figure lb; paper/fibreboard and sometimes from metal. Wooden pallets typically consist of three or four support stringers that support several deckboards, on top of which goods are placed. Square or nearly square pallets help a load resist tipping. Goods or shipping containers are often placed on a pallet secured with strapping, stretch wrap or shrink wrap and shipped. Pallets make it easier to move heavy stacks and are extremely adaptable, not being limited to specific dimensions of height, weight or bulk size as such. Loads with pallets under them can be hauled by forklift trucks of different sizes, or even by hand-drawn pallet trucks. Not only are there grades of durability, heavy weights need to be supported by sufficiently strong pallets. Most pallets can easily carry a load of 1,000 kg (2,205 lb), although, operators must be aware that lightweight pallets may be provided for less significant loads and the load rating must always be confirmed prior to use, given that group transport organisations exist, where pallet products are shared between groups of users, for different types of goods.

In some areas of logistics, it has been found that the pallet has become the structural foundation of a unit load which allows handling and storage efficiencies. For example, a unit load device (ULD) typically comprises a container used to load luggage, freight and mail on aircraft that allows a large quantity of cargo to be bundled into a single unit. Since this leads to fewer units to load, it saves ground crews time and effort and helps prevent delayed flights. Each ULD has its own packing list (or manifest) so that its contents can be checked and tracked. Further, the extensive use of 40' and 20' containers for transport has spurred the use of pallets because such shipping containers provide smooth and level surfaces suitable for easy pallet movement and bulk stacking of a large number of palletized loads. It is presently understood that, over half a billion pallets are made each year and about two billion pallets are in use across the United States, for example.

Typical pallet sizes are: 1200 x 1000mm; 1200 x 800mm; 48" x 40"; being three of six ISO (International Standards Organization) sanctioned standard pallets, although there is a plethora of different sizes for specific tasks, globally. The fork tines of a fork lift or other lifting device may have limited access to a pallet, being limited to only one side, to two sides or can be provided on all four sides (1-, 2-, or 4 way entry). Pallets are reusable packaging items. Every pallet that is built could potentially be used and used again until such a time when it will need to be replaced. The lack of a single international standard for pallets causes substantial continuing expense in international trade. A single standard is difficult because of the wide variety of needs a standard pallet would have to satisfy: passing by or through doorways, placing within standard containers and unit load devices (ULDS), noting that weight, size and bulk affect the use of a standard type of load and use of a standard can reduce labour costs.

In order to maximise the storage capacity of a warehouse pallets are placed upon pallet racks, as shown in Figure 2a ; the common frame comprising at least four vertical posts is fitted with beams that can be connected at various levels to the posts, whereby to provide racking systems which can be adjusted in height to provide a number of support platforms each for individual pallets. Whilst pallets can be stacked one atop another, this can be inconvenient; stabilization can be required and, not infrequently, can be hazardous, with a risk of breakage of goods through poor handling and a potential collapse over time.

With regard to commercial vehicles and the load capacity of such, especially of the curtain sided type, whereby access is afforded to a pallet lifter, such as a fork lift truck, from the side of the vehicle. Additionally, the goods will need to be made secure with straps, locking catches etc.. It will need to be borne in mind that when a commercial vehicle goes around a corner,- centrifugal forces will apply to the loads; the higher a load is situated, the greater such forces shall be. Figure 2b i - iii show how loads can be accompanied within a standard pallet height x; in contrast, Figure 2b iv shows how easily an unusual load can cause problems in logistics, when a standard height pallet cannot be used; no stacking is possible etc.

Figure 3a shows a pallet with four boxes 32 placed thereon. However, many pallets are loaded with goods such that it is not intended to have further pallets stacked upon a first pallet, such as the case of the pallet 30 per Figure 3b, which is loaded with a load 33 in a central area of the pallet 30, or where shrink/stretch plastics has been wrapped about a load, whilst providing greater security, minimising the possibility of movement of the goods in transit, can dispense with any sides to a palletised load, preventing any possibility of stacking. Additionally, once placed upon a lower pallet, it is frequently the case that the pallet needs to be slid or offset across the tops of one or more pallets. For example with a curtain sided lorry a fork lift driver may not have been correct in the order of pallets being placed upon a truck and it may be desired to shift the loaded pallet sideways. Equally, in a warehouse, as a layer of palletised goods are built up, it may be desired to slide pallets of further layers backwards, from a front access point towards a rearward stack of pallets. Referring to Figure 3c there is shown a pallet assembly 34 having first and second base and lid members 35, 36, with the base member providing a forklift tine access channel on an underside together with a peripheral ledge support 37 for cylindrical sleeve 38, the cover 36 having guide ribs to enable the fitment of the sleeve at the top. This requires the use of at least two personnel to erect such a container of this type, since the sleeve needs to be slot into the base member and into the cover member.

Object of the Invention

The present invention seeks to provide a solution to the problems addressed above. The present invention seeks to provide a system that can enable goods to be securely and reliably horizontally, vertically and offset stacked, despite different sizes of base support members such as pallets, if any, whereby wasted volumes arising from the presence of irregular loads, pallets or pallets of different levels or different load ratings in storage and transport can be minimized.

Furthermore, the present invention seeks to provide a system for both pallet- borne goods and non-pallet-borne goods that protects the goods and enables stacking.

Statement of Invention

In accordance with a general aspect of the invention, there is provided a storage/transport assembly comprising first and second wall members and a cover; wherein the first and second wall members each comprise first, second and third panels, each adjacent pair of panels being hingedly arranged with respect to each other; wherein the first and second wall members are capable of being flat packed when not in use; wherein, in use, the first and second wall members provide upstanding walls about a generally rectangular cuboid storage/transport volume, the first and third panels of one wall member being arranged in facing relationship with third and first panels of the other wall member to define said storage/transport volume, the walls extending from feet operably in contact with a base support surface and rise to an uppermost lip operable to support a lower surface of said cover, at least one of the walls having at least one aperture to permit access for at least one tine of a lifting device; and, wherein the cover is operable to provide a closure extending over the storage/transport volume the walls, the cover having engagement means to locate with the uppermost lip of the walls and enable secure lateral fitment therewith and is operable to provide an upper support surface. By having a wall which can be folded in a flat fashion when not in use, the actual useful storage space of a warehouse, racking system, loading bay, lorry, train wagon or other form of ground / working area support surface can be increased. In a commercial vehicle delivery system, pallets loads can be protected and stacked; equally, non- palletised loads can be protected and stacked; whilst on a return journey a totally different type of load can be transported with the transport/storage system of the present invention being stored with a reduced space configuration, whereby to assist in a logistics business, by reducing wasted transport volume and/or wastage arising from a single-use transport/storage system.

Conveniently, the engagement means of the cover comprises one or more downwardly directed channels which limit movement of the upstanding lip surfaces of the walls upon placement of the cover on the walls. This slot-together feature has been shown to add considerable integrity to the transport/storage assembly. Additionally, the upper surface of the cover can be provided with upwardly directed features which can engage with the feet of an additional transport/storage assembly stacked thereon or allow the placement of a subsequent pallet.

The wall members of the transport/storage assembly can be fabricated from one or more types of panel including extruded polystyrene, polyurethane foam, expanded polystyrene, cardboard, laminated polyurethane foam, laminated expanded polystyrene. The laminate face can comprise, for example, one of card, plywood, polypropylene, aluminium or steel. The wall members can comprise panels and hinges, wherein the hinges enable the panels to be substantially rigid. If the wall members are formed from cardboard, then the cardboard could be folded to provide hinges integral with the cardboard structure. The cardboard employed can be selected from common grades such as single, double, triple or quadruple corrugated cardboard. Conveniently, such cardboard is treated with at least one of wax, resin, paint or other known waterproofing methods, whereby full waterproofing can be provided. Corrugated plastics panels can also be conveniently be employed.

It is recognised that, conveniently, a transport/storage assembly in accordance with the invention comprises a wall arrangement defining four panels, the dimensions of which enable the walls to be placed about or in close/abutting relationship with a pallet base or other type of product to be transported or stored or when placed upon a support surface.

The cover is conveniently manufactured from a variety of materials, such as thermo-formed plastics, moulded fibreboard, a formed plastics or moulded resin impregnated fibre or similar. An aperture or cut-out can be defined within a wall of the wall members, to enable access within the assembly. Linking members can be provided whereby to link adjacent assemblies other horizontally or vertically one with respect to the other, by means of coupling holes, straps and latches arranged along edge portions of the assemblies. Security tags can be employed to secure loads for transport and to reduce or minimise interference.

The base support surface upon which transport/storage assembly is placed can comprise one of a ground surface (generally), a floor associated with one of a support bench/storage - racking system associated a stores area, a workshop/office/storage area, a load floor of a transport vehicle and a cover of another cylindrical transport/storage assembly. By having a wall which can be folded in a flat fashion when not in use, the actual useful storage space of a warehouse, racking system, loading bay, lorry, train wagon or other form of ground / working area support surface can be increased. Conveniently, in respect of the first and/or second wall members, one of or both of respective first and third panels have radiused corners between an upstanding edge and a top edge of each said panel. This provides an advantage when positioning the components, especially when a user positions the lower edge of a second, middle panel along a ground support surface - such that there is an acute angle as between the ground surface and the inclined Second panel - and pivots the wall member, such that the lower edges of the first and third wall members can be brought towards the ground support surface. A pallet assembly in accordance with the present invention may be assembled in a rapid and expeditious manner. The two parts making up the pallet assembly may be stacked for storage in a relatively small space, conveniently being prior attached to a panel for a container, and may be associated with a container also arranged in a flat-pack style. In accordance with a still further aspect of the invention, there is provided a method of fabrication of a transport/storage assembly, the method comprising the steps of arranging the wall members in an upright position and placing the lid upon the upstanding element of the wall members.

Brief Description of the Figures

For a better understanding of the present invention, reference will now be made, by way of example only, to the Figures as shown in the accompanying drawing sheets, wherein :-

Figures la - lc illustrate three known forms of pallet;

Figure 2a and 2bi - biv respectively illustrate an arrangement of pallets upon racks and show how pallets are typically loaded;

Figure 4i - 4iv show a first embodiment of a transportation and storage system in accordance with the invention;

Figure 4v - 4vi show a second embodiment of a transportation and storage system in accordance with the invention;

Figures 5i - 5iii show a general view and two underside views, respectively, of a lid in accordance with the present invention;

Figures 5iv- 5v detail how a load can be distributed across a lid in accordance with the invention;

Figures 6i - 6ii show two variations in a container in accordance with the invention;

Figures 7i -9ii show further variants of the present invention;

Figures 7a and 7b show the construction of one transport/storage assembly with a load, prior to and subsequent to the placement of a cover;

Figures 7c and 7d show how expanded and complete views of first and second transport/storage assemblies in accordance with the invention being stacked;

Figures 7e - 7i detail aperture and aperture reinforcement features; Figures lOi, ii show a further variant detailing a form of attachment between two adjacent containers in accordance with the invention;

Figure lOiii shows another form of attachment between two adjacent containers in accordance with the invention; and,

Figures 11 & 12 shows how the containers in accordance with the present invention can be, stored, stacked and supported as in a warehouse or vehicle.

Detailed description of the Preferred Embodiments

There will now be described, by way of example only, the best mode contemplated by the inventor for carrying out the present invention. In the following description, numerous specific details are set out in order to provide a complete understanding to the present invention. It will be apparent to those skilled in the art, that the present invention may be put into practice with variations of the specific.

With reference to Figures 4i and 4ii, there is shown an example of a pallet 20 surrounded by walls sections 41 and 42; the pallet 10 in use supporting a load, the walls comprising first 41i, 42i, second 41ii, 42ii and third 41iii, 42iii rectangular sections, which surround the pallet enclosing any load placed thereupon. In this embodiment, the widths of the central walls is the same such that when the walls are assembled and connected via fastening means such as, hook and loop fastening means, where the hook patch 44, and loop patch 45 are placed, respectively upon inside and outside surfaces of walls 4ii - 42i and 42ii - 41ii. Figure 4iv shows the present invention with a lid or cover in place, which is conveniently and simply placed upon the upstanding walls, whereby to provide a simply erected, fully enclosed container storage device. It will be appreciated that one of the central panels has a reduced width such that the first and third walls of one wall panel fit inside the corresponding first and third walls of the other wall panel, but such a variation immediately doubles the number of types of wall panel that one must store and, of course, would incur delay in use, since operators would need to perform an extra check in the erection of containers in accordance with the invention. Whilst the pallet 10 is not shown in any great detail, the example shown is manufactured from wood and is a four-way entry pallet, wherein the tines of a fork lift or similar tined lifting device can insert its tines through gaps 46 typically having a lower-most height of 100 - 120 mm, but this will vary, dependent upon the material of manufacture of the pallet and the load to be supported. Applicants have therefore been able to reduce the number of components in a transport and storage system to one type of a flat-pack sidewall and cover therefor. In the manufacture of development products, DS Smith PLC, a leading provider of corrugated packaging, supplied high performance corrugated board specifically developed for heavy-duty packaging applications. There are several standard wall board grades, thicknesses ranging from 3mm, to 15mm, with differentiators including the weight of the papers and the flute profiles, as well as the number of corrugations, the use of wet strength resins and wet strength adhesives to give good-excellent performance in moist or humid conditions. It is also possible to coat the board to provide further moisture protection, for example.

By the use of cardboard products, in the manufacture of containers in accordance with the invention, it will be appreciated that the product can be recycled at the end of a useful life - which will vary dependent upon specific needs / and design lifetime. Cardboard wall members can be reinforced to a degree suitable for purpose: conveniently, the cardboard wall members can be made from industry standard single, double, triple or quadruple corrugated cardboard. In view of the ability of untreated cardboard to absorb water from precipitation or from the atmosphere, the cardboard should be adequately treated, by wax, resin, paint or other known waterproofing methods. When using corrugated board formed from 440gm ^"2 wet strength Kraft paper, this type of board has a weather resistance which satisfies a 2 hour water immersion test without any ply separation. In addition to a requirement for waterproofing, in order to strengthen the material, one or more of a number of options may be selected : the number of layers of sheets may be increased - e.g. for a corrugated board, the sheets as a whole, or merely just the corner sections, can be reinforced so that they have two, three of more layers; any corrugated flutes could be filled with elongate support members or strengthening members, which could be plastic rod, metal, wood or any of a number of alternative materials which can be placed within the corrugation flutes, conveniently glued or otherwise permanently attached. Distinct materials such as batons or, preferably, sheet materials can also be provided where extra strength is required. With reference to Figures 4v & 4vi, corrugated plastics were employed, which plastics panels were provided with rolled edges, making the finished edges more easily handled by personnel. Corrugated plastic is typically made from polypropylene which is capable of being recycled.

In use, the sidewalls can be employed to surround loads in their own right or, for example, loads placed upon pallets; subsequently a cover can be placed upon the sidewalls, conveniently engaging with the upstanding edges or lips of the sidewall, to provide a secure enclosure for the load. Therefore the load is shielded from dust and other interference; the load cannot be tampered with easily and further loads can be placed upon the cover. In tests, a widely available (and therefore available at an economical cost) 15mm board has been used for the wall members, with respect to a container suitable to surround a Euro Pallet - having dimensions of 1250mm x 1000mm. This has been found to provide sufficient strength to support loads approaching lOOOKg from a cover, but a safe working limit upon the covers would be 300-600Kg. Obviously different grades of cardboard will provide different working weight limits. Using standard 15mm thick corrugated cardboard sidewalls, for example, as a euro- pallet enclosure, it has been determined that a weight of lOOOKg can be supported - meaning, that a working limit of 300-600Kg can be defined, taking into account potential deterioration over time and possible incompetence of handling in use. Moreover, it has been found that standard height loads can be safely stacked up to three high, with health and safety issues necessitating a limit in view of possible overloading in use. Notwithstanding this, the skilled man will realise that a greater number of half-height transport/storage assemblies can be stacked. Compression tests have been conducted and positive results have been realised with containers made in accordance with the invention withstanding between 2800 - 3200 kgf (27.46 - 30.4KN) - in a static load compression test. The Compression testing was conducted on a Macklow Smith compression tester with fixed platens and a load speed of lOmm/min. The mean Peak BCT load achieved was 3035kgf (29.76KN). These tests were performed using devices calibrated to International Standards and the tests are based around the BS1610 standard.

Figure 5i shows a lid in accordance with the present invention which can be conveniently be formed as a twin-wall thermo-formed lid, with upper-surface upstanding linear features 47 and pyramids 48 operable to allow / facilitate alignment of further containers and /or pallets thereupon. With reference to Figures 5ii & 5iii, there are shown, respectively, views of an underside and a partial section through a lid. Figure 5ii shows the underside of the lid in perspective, with a channel 50 defined between an edge 49 and an upstanding centre portion. In cross-section, per Figure 5iii, it can be seem that the channel 50 narrows, which can assist in placement of the lid over upstanding lips of the walls 41, 42. The channel need not engage, by way of a friction fit, for example (although this may be desired in certain circumstances) and can be sufficiently wide for two upstanding wall members (on the sides that overlap). Additionally, the space between the two walls can be employed to insert thermally insulating foams, such as polyurethane foam, which can also assist in increasing a rigidity of the structure, dependent upon a suitable choice of foam. It will be appreciated that other materials can be used. For example, the cover could also comprise formed plastics or resin impregnated fibre moulded elements, strengthened as appropriate.

Figures 5iv and 5v show how the lids permit the stacking of further loads or the placement of further loads to be placed upon or act upon the lids in accordance with the system of the present invention. Figure 5iv shows how further loads can be stacked one atop another in a simple fashion, the lid spreading the load so that the upstanding lips of the walls absorb the weight. Figure 5v shows how the forces 80 arising from the weight of a barrel 79 upon a lid 59 are act through the walls of a container by the use of the laminated lid 59. Note that because of the aperture 52 for the forks of a lifting mechanism such as a fork lift truck, strengthening means can conveniently be applied to protect the aperture form damage. For additional bearing strength of the lid, the single aperture 52 could be replaced by two single apertures, to enable weight to be transferred to a lower support surface, although the central support may well get easily damaged in use through inadvertent positioning of fork lift truck forks against the cardboard and the support about the aperture 52, in particular.

Referring how to Figures 6i and 6ii, optional apertures 53, are placed within the walls 41, 42, to assist in placement of the walls about a pallet or load / storage volume. Additionally, the aperture 52, for the tines of a fork lift can comprise two separate apertures (as also shown in Figure 4) or a single aperture. In use, the tines of a fork-lift truck are introduced into the region defined by the aperture, which is conveniently at least 140mm high, whereby when a palletised load is present within the transport/storage assembly and it is desired to move the palletised load, then the tines of the lifting device are inserted so that they pass through the assembly and extend to the other side. Initially the tines contact the underside of the pallet and lift the pallet and then engage the underside of the walls defining the top of the aperture.

Figure 7i shows a still further variant, wherein there are two types of wall panel, 41 and 42'. As shown in greater detail in Figure 7ii, wall member 42" has first and third panels having an arcuate shape, whereby to ease installation from one side, since one can place the base of panel 42" where it should lie when upright but with the outside wall at an angle less than 90° to the vertical, whereby the top edge of the sidewall is brought adjacent the top corners of the first and third panels of panel 41. It will be understood that since both first and third sidewall portions of the panel 42 sit inside the wall panel 41, then the length of the central panel ( ) of wall panel 42' are reduced with respect to length (I) of wall panel 41. This system has the disadvantage of the panels being distinct. In another alternative, with reference to Figure 8, the third panel of each panel 41", 42" has a curved top edge to assist in placement of the wall panels. Figures 9i and 9ii show an additional variation wherein the third panel of each panel is of the order of half the length of the corresponding first panel. In figures 7 - 10, the apertures 52 for fork lift tines are not shown for convenience. Figure lOi shows a still further variant wherein a fourth panel 41 extends from the first panel and is provided with hook and loop fastening means or re-usable / replaceable adhesive tape where, with reverence to figure ION, two adjacent panels 41"" can be fastened together. Using the same principles, adjacent lids could be fastened together for securing goods. Additionally, there may be provided holes for security tags to be inserted, to provide tamper-evident indications that a container has not been moved, once arranged around a load. It has been found that by the provision of support member inserts about the downwardly directing edges of the apertures for the tines in the sidewall, the lower surface is sufficiently strengthened to accept repeated use of tines associated with fork-lift trucks and other types of tined lifting apparatus.

Figure 11 shows how the transport and storage embodiments made in accordance with the invention can be stacked one atop the other and side by side, without pallets being present. Figure 12 shows how a number of transport and storage device in accordance with the invention can be provided within a warehouse 120. Similar systems can be provided for within the load area upon a flat load bed of a lorry etc. Equally, small vans can be provided with a number of such transport and storage devices of reduced height, whereby the effective load capacity is increased substantially, which is especially useful for local delivery purposes. By having half-height transport and storage devices, the number of load areas can be increased, whilst being removable from the vehicle, upon the unfastening of any straps and linking members between adjacent devices - whether to the side or above and below. It will be appreciated that if a larger item needs to be carried, the storage devices, with pallets or not can be either removed from the van or lorry or be stored in a flat-pack arrangement, to enable a particular load to be carried.

As is known, various systems of temperature control can be implemented, with the use of foam or vacuum insulation panels (and lid), together with the use of view of coolant packages 143 such as phase-change medium (PCM) packages which are selectively cooled to provide a temperature profile for a particular class of good for a period of time - typically 24 - 120 hours, although such temperature profiles can only be maintained in the event that the a load volume is sealed, and in view of the apertures that are provided for the tines of a fork lift truck etc., the issue of temperature control is suitably addressed by the nature of the load carton retained within the container of the present invention.

Whilst the present invention enable greater flexibility in the positioning of loads, whether employing a pallet or not, and the stacking thereof, such stacking should only be performed subject to the ability of base-level transport/storage assemblies to take additional weight. Dependent on the height, strength and stability of the assemblies and the ability of the operator to see clearly, taller stacks may only be built following detailed consultation with the manufacturer or other competent authority. To assist in the management of closely stacked and closely coupled load enclosures or pallet enclosures, the wall members should be connectable with their associated pallets using suitable fastening means. In particular, it has been found that straps and / or panels with cooperating hook and loop fastening means provide easily applied and easily removed fastening means, although a locking bolt or similar, noting that such locking bolts, should preferably present a flush external surface finish, to enable adjacent coupling, but ideally such flush bolts can assist in the close coupling of transport/storage assemblies. The use of coloured locking straps and panels can assist in a ready indication of attachment of adjacent containers, which is not necessarily important for static storage systems, but could be quite important for maintenance of stability of loads in vehicles, ships etc. The covers can also be coupled together using similar coupling elements. In a still further modification, closing apertures and/or transparent wall sections could be defined in the walls of the container whereby access to associated documents and so-called "floating objects" and/or visibility could be provided to allow, for example, visual confirmation of contents. Conveniently, at least one of a lock, plastics security tie, crimped wire tie or similar is present whereby to provide control over access through to the inside of the container, noting that such apertures will need to be provided through two separate walls, where there is a double wall thickness.