EP0670268B1

EP0670268B1 - Pallet for plates stacks, carrier and transport structures comprising said pallet and methods of packing and unpacking said plates stacks

Info

Publication number: EP0670268B1
Application number: EP19950301327
Authority: EP
Inventors: Nobuo Iwasaki; Koichi Tsuruta; Yushikoh Naka
Original assignee: Toyota Steel Center Co Ltd
Current assignee: Toyota Steel Center Co Ltd
Priority date: 1994-03-01
Filing date: 1995-03-01
Publication date: 1997-08-06
Anticipated expiration: 2015-03-01
Also published as: EP0670268A1; JPH07242237A; JP2732216B2

Description

The present invention relates to pallets for stacks of plates; to methods for storing, transporting, packing and fastening stacks of plates; to structures for fastening and storing stacks of plates; to carriers doubling as pallets; and to methods for storing pallet-equipped carriers or carriers doubling as pallets after packages carried thereby are unloaded therefrom. The invention is intended for use in applications of transport, e.g. applications involving containers for efficiently accommodating various stacks of a plurality of plates having different plane figures (steel members, plastic plates, etc.).
There exists a conventional method for storing CKD (complete knocked down) parts in module boxes for export purposes. This method involves having the boxes manufactured in a modular manner relative to the inner dimensions of containers. The parts are placed in these boxes which are in turn accommodated in each container. A major disadvantage of this method is its inability to transport stacks of plates efficiently.
Conventionally, stacks of plates are packed and transported generally by the method illustrated in Figs. 24 through 29 attached. Specifically, steel plates of a given shape are first piled into a stack 4. The stack 4 is fastened temporarily by a provisional band 3, with F-shaped fittings 921 interposed between the stack and the band. The stack 4 thus bound is topped with a top plate 92 (Fig. 24).
Meanwhile, a rust preventive sheet 93 and a cloth sheet 94 are placed over a wooden skid 95 separately prepared. With its provisional band 3 and its top plate 92 removed, the stack 4 is then moved onto the sheet-covered skid 95 (Fig. 25). After the stack 4 is wrapped and packed, dolly blocks 96 are attached to the corners of the packed stack 4 (Fig. 26). On top of the dolly blocks 96 are placed side plates 97 (Fig. 27). With the side plates 97 in place, the stack 4 is again topped with the top plate 92. Over the top plate 92, traverse battens 82 are placed and strapped with a hoop band 3 each (Fig. 28). Likewise, longitudinal battens 83 are placed over the stack 4 and strapped with a hoop band 3 each. This completes the preparation of a plate stack package (Fig. 29). If such packages were transported in containers for export overseas, each package would have to be fastened using large amounts of wood members nailed to the container floor so as to prevent moving of the plate stacks. For domestic haulage, the stacks of plates are each fastened to a skid with hoop bands. The stacks on their skids are then loaded onto the load-carrying platform of a truck. It takes time to load these stacks of plates on the truck because the shapes and balances of the stacks must be optimally taken into account for damage-free transport.
The above-described conventional methods for packing and transporting stacks of plates have the following major disadvantages:

(1) It is difficult to fasten stacks of plates to skids and the stack-mounted skids to the interior of containers. The difficulties involved need to be dealt with by many people working long hours.
(2) Large quantities of junk and scraps are produced upon unloading from packing and fastening materials (such as metal side plates, top plates, wooden skids and battens).
(3) It is difficult to stack many varieties of plates having different shapes and sizes on each pallet.
(4) It is especially difficult to lash the stacks of plates inside the container. To perform the lashing requires special techniques.
(5) Contact in transit between the stacked plates must be dealt with by meticulous packing and by use of appropriate shock absorbing materials.
(6) Stacks of plates, if mounted one on top of another in a conventional manner, can result in localized damage under their dead weight. This means that outer plates of automobiles, for example, cannot be transported in stacks mounted one upon another. The result is a drastically reduced efficiency of transport.
(7) It is especially difficult to fasten stacks of profiles having plane figures of complicated curves (e.g., profiles 4a and 4c shown in Fig. 3). This is because fastening hoop bands, applied to such profiles, can only hold them diagonally and hence insecurely. Furthermore, it is extremely difficult to fasten securely the profiles due to their complicated shapes inside the rectangular interior of containers or to store them therein efficiently with a minimum of superfluous space left. Under the above-described conventional methods of fastening and packing, stacks of profiles have yet to be exported overseas.
(8) It takes a lot of time and effort to unpack the fastening and packing materials and the associated structures. It also takes large amounts of time and effort to move around the stacks of plates thus prepared.

US-A-3675595 discloses a pallet adapted for fastening stacks of plates, the pallet having a plurality of notches in its edges so that rectangular plates of different sizes can be stacked on the said pallet, the notches receiving fasteners for fastening different stacks of plates to the pallet, and a stack of plates secured to the pallet by fasteners located in the said notches. The notches cannot be made very deep because otherwise the pallet would be weakened. This also means that only articles which generally conform to the shape of the edge of the pallet can be accommodated.
The present invention seeks to overcome or alleviate one or more of the disadvantages of the prior art and to provide pallets for stacks of platesbeing used selectively to fasten a given stack of plates having a given plane figure; a method for storing easily and efficiently stacks of a plurality of profiles (especially those with curved surfaces) or plates having different plane figures inside a transport container; a method for transporting easily and efficiently the stacks thus packed; a method for packing and fastening the stacks of plates on pallets; structures for fastening and storing the stacks of plates for storage or for transport; carriers doubling as pallets; and a method for storing and sending back pallet-equipped carriers and carriers doubling as pallets after the packages carried thereby are unloaded therefrom.
The inventors of this invention did research on the system for transporting easily and efficiently stacks of profiles or plates having different plane figures. The findings that the inventors came up with have made this invention possible. The findings basically comprise: making holes on pallets in keeping with the plane figures of diverse plates to be stacked thereon; standardizing such pallets dimensionally with respect to carriers carrying them; and standardizing these carriers dimensionally relative to transport containers.
In carrying out the invention and according to a first aspect thereof, there is provided a structure comprising a pallet adapted for fastening stacks of plates, the pallet defining a plurality of apertures in appropriate positions peripheral to outer edges of a plurality of different plates to be stacked on said pallet, said apertures being suitable for receiving fasteners for selectively fastening a given stack of plates, a stack of plates disposed approximately within the geometry formed by an appropriate number of apertures for receiving fasteners for fastening the stack to the pallet, and a plurality of fasteners threaded through said appropriate number of apertures so as to fasten said stack of plates to said pallet, characterised in that the apertures are holes in the pallet and the fasteners are threaded through the said holes. In a preferred form of this aspect there is provided pallets for stacks of plates comprising of: at least one pallet having a plurality of band holes made thereon in appropriate positions outlining peripherally the plane figures of a plurality of different plates to be stacked on the pallet, the band holes being used selectively to fasten a given stack of plates having a given plane figure, and a plain figure of either the single pallet or the combination of pallets is corresponding substantially to a plain figure of a carrier fastened thereunder.
According to a second aspect there is provided a method comprising the steps of providing a pallet according to the first aspect of the invention, positioning a stack comprising a plurality of different plates on the pallet with holes defined by the pallet being peripheral to outer edges of said plates;
threading a plurality of fasteners through appropriate holes of the pallet so as to fasten said stack of plates to said pallet;
fastening said pallet together with said stack of plates to a carrier having inwardly collapsible erectors mounted on four corners thereof, said erectors allowing a plurality of pallets along with the stacks of plates to be piled one upon another in a layered manner, the carrier having a periphery defining an area substantially corresponding to the periphery of the pallet or of a combination of such pallets adjacent to one another;
storing the carrier together with the pallet into a transport container, the transport container having a periphery corresponding substantially to the periphery of the carrier or of a combination of such carriers adjacent to one another;
erecting said erectors of the carrier to support on top thereof another pallet with a stack of plates fastened thereto.
In a preferred form of this aspect there is provided a method for storing stacks of plates, comprising the steps of: providing at least one pallet 1 having a plurality of band holes made thereon in appropriate positions outlining peripherally the plane figures of a plurality of different plates to be stacked on the pallet 1, the band holes being used selectively to fasten a given stack of plates 4 having a given plane figure; positioning the stack of plates 4 on at least one pallet; threading a plurality of fastening bands 3 through the appropriate band holes so as to fasten the stack of plates 4 to the pallet; fastening the pallet 1 together with the stack of plates 4 to a carrier 2 having inwardly collapsible erectors mounted on the four corners thereof, the erectors allowing a plurality of pallets 1 along with the stacks of plates 4 to be piled one upon another in a layered manner, the plain figure of the carrier 2 corresponding in area substantially either to a single pallet or to a combination of pallets; storing at least one carrier 2 together with the pallet 1 into a transport container, the plane figure of the transport container corresponding in area substantially either to a single carrier or to a combination of carriers; and erecting the erectors of each carrier 2 to support on top thereof another pallet with a stack of plates fastened thereto.
The stacks of plates include those of steel plates, various metal plates, plastic plates and plywood plates, among others. The word "fasten(ing)" refers to any action of strapping, binding, fitting, engaging or otherwise securing objects in a subsequently detachable manner. The definitions will apply hereunder.
According to a third aspect of the invention which is subordinate to the second aspect thereof, there is provided a method for storing stacks of plates, further comprising the steps of: placing a sheet-like packing material over a given stack of plates; positioning and setting a pallet where appropriate on top of the sheet-like packing material; turning upside down the assembly of the stack of plates, of the sheet-like packing material and of the pallet; and folding any part of the sheet-like packing material left out of the stack of plates so as to wrap and pack the stack on the pallet.
According to a fourth aspect of the invention, there is provided a method for transporting stacks of plates, comprising the step of transporting the stacks of plates stored according to the method of the second or third aspect of the invention, the stacks of plates to be transported being loaded on pallets which in turn are mounted on carriers as defined in the second or third aspect of the invention.
According to a fifth aspect of the invention, there is provided a method for packing and fastening stacks of plates, comprising the steps of: placing a sheet-like packing material over a given stack of plates having different plane figures; positioning and setting a pallet 1 where appropriate on top of the sheet-like packing material, the pallet 1 having a plurality of band holes in appropriate positions outlining peripherally any of the different plane figures of the plates, the band holes being used selectively to fasten any of the stacked plates; turning upside down the assembly of the stack of plates, of the sheet-like packing material and of the pallet 1; folding any part of the sheet-like packing material left out of the stack of plates so as to wrap and pack the stack; and threading a plurality of fastening bands through the band holes so as to fasten the packed stack of plates to the pallet 1.
According to a sixth aspect of the invention, there is provided a structure for fastening stacks of plates, comprising: a pallet 1 having a plurality of band holes in appropriate positions outlining peripherally any of different plane figures of a plurality of various plates in a stack, the band holes being used selectively to fasten any of the stacked plates; a stack of plates 4 disposed approximately within the geometry formed by an appropriate number of band holes located where appropriate; and a plurality of fastening bands 3 threaded through the appropriate number of band holes so as to fasten the stack of plates 4 to the pallet 1.
According to a seventh aspect of the invention, there is provided a structure for fastening stacks of plates, further comprising: a pallet 8 loaded with a stack of plates, which has the fastening structure of the sixth aspect of the invention; and a carrier 2 to which the pallet 8 is fastened and which has inwardly collapsible erectors mounted on the four corners thereof, the erectors allowing a plurality of pallets 8 along with the stacks of plates to be piled one upon another in a layered manner.
According to a eighth aspect of the invention which is subordinate to the seventh aspect thereof, there is provided a structure for storing stacks of plates, comprising: a transport container 5; and a plurality of carriers which may be piled one upon another in a layered manner inside the transport container 5 and which carry pallets with stacks of plates loaded and fastened thereon according to the fastening structure of the seventh aspect of the invention; wherein the plane figure of either one carrier or a combination of carriers constituting one layer is substantially equal to the plane figure of the transport container 5; and wherein the plane figure of either one pallet or a combination of pallets constituting one layer is substantially equal to the plane figure of each carrier.
According to an ninth aspect of the invention which is subordinate to the eighth aspect thereof, there is provided a structure for storing stacks of plates wherein each of the carriers constituting one layer has the length composed of any of a plurality of unit lengths equally dividing the length of the transport container in the loading and unloading direction thereof, and wherein each pallet has the length composed of any of a plurality of unit lengths equally dividing the length of one of the carriers in the loading and unloading direction thereof.
According to a tenth aspect of the invention, there is provided a method for storing pallet-equipped carriers with stacks of plates removed therefrom, comprising the steps of: unloading from a transport container the carriers carrying pallets with stacks of plates mounted thereon according to the storing structure of the eighth or the ninth aspect of the invention; performing both the removal from the carriers of the pallets with the stacks of plates mounted thereon, and the collapsing of the erectors at the four corners of each of the carriers, the two steps being accomplished in a desired order; fastening the pallets to the carriers after the stacks of plates are removed from the pallets; and storing the pallet-equipped carriers into the transport container in a layered manner.
According to a eleventh aspect of the invention, there is provided a carrier doubling as a pallet, comprising: a plurality of band holes in appropriate positions outlining peripherally any of different plane figures of a plurality of various plates in a stack, the band holes being used selectively to fasten any of the stacked plates; and inwardly collapsible erectors mounted on the four corners of the carrier, the erectors allowing a plurality of stacks of plates to be piled one upon another in a layered manner.
According to an twelfth aspect of the invention, there is provided a method for storing stacks of plates, comprising the steps of: disposing a stack of plates 4 where appropriate on each carrier doubling as the pallet as defined in the eleventh aspect of the invention; threading a plurality of fastening bands 3 through band holes of the carrier so as to fasten the stack of plates 4 to the pallet; storing into a transport container at least one carrier doubling as a pallet with the stack of plates 4 fastened thereto, the plane figure of either one carrier doubling as a pallet or a combination of carriers doubling as pallets being substantially equal in area to the plane figure of the transport container; and erecting the erectors of each carrier to support on top thereof another carrier doubling as a pallet with a stack of plates fastened thereto.
According to a thirteenth aspect of the invention which is subordinate to the twelfth aspect thereof, there is provided a method for storing stacks of plates, further comprising the steps of: placing a sheet-like packing material over a given stack of plates; positioning and setting the carrier doubling as the pallet where appropriate on top of the sheet-like packing material; turning upside down the assembly of the stack of plates, of the sheet-like packing material and of the carrier doubling as the pallet; and folding any part of the sheet-like packing material left out of the stack of plates so as to wrap and pack the stack on the carrier doubling as the pallet.
According to a fourteenth aspect of the invention, there is provided a method for transporting stacks of plates, comprising the step of transporting the carriers doubling as pallets storing stacks of plates as defined in the twelfth or the thirteenth aspect of the invention.
According to a fifteenth aspect of the invention, there is provided a method for packing and fastening stacks of plates, comprising the steps of: placing a sheet-like packing material over a given stack of plates having different plane figures; positioning and setting the carrier doubling as the pallet as defined in the eleventh aspect of the invention, where appropriate on top of the sheet-like packing material, in such a manner that the erectors of the carrier will be located downward; turning upside down the assembly of the stack of plates, of the sheet-like packing material and of the carrier doubling as the pallet; folding any part of the sheet-like packing material left out of the stack of plates so as to wrap and pack the stack; and threading a plurality of fastening bands through band holes of the carrier doubling as the pallet so as to fasten the packed stack of plates to the carrier.
According to a sixteenth aspect of the invention, there is provided a structure for fastening stacks of plates, comprising: a carrier 6 doubling as a pallet as defined in the eleventh aspect of the invention; a stack of plates 4 disposed approximately within the geometry formed by an appropriate number of band holes on the carrier 6 doubling as the pallet; and a plurality of fastening bands 3 threaded through the appropriate number of band holes so as to fasten the stack of plates 4 to the pallet.
According to a seventeenth aspect of the invention which is subordinate to the fifteenth aspect thereof, there is provided a structure for storing stacks of plates, comprising: a transport container; and a plurality of carriers which may be piled one upon another in a layered manner inside the transport container and which carry stacks of plates loaded and fastened thereon according to the fastening structure of the sixteenth aspect of the invention; wherein the plane figure of either one carrier doubling as a pallet or a combination of carriers doubling as pallets constituting one layer is substantially equal to the plane figure of the transport container.
According to a eighteenth aspect of the invention which is subordinate to the seventeenth aspect thereof, there is provided a structure for storing stacks of plates, wherein each of the carriers doubling as the pallets constituting one layer has the length composed of any of a plurality of unit lengths equally dividing the length of the transport container in the loading and unloading direction thereof.
According to an nineteenth aspect of the invention, there is provided a method for storing carriers doubling as pallets with stacks of plates removed therefrom, comprising the steps of: unloading from a transport container the carriers doubling as pallets carrying stacks of plates mounted thereon according to the storing structure of the seventeenth or the eighteenth aspect of the invention; performing both the removal from the carriers of the stacks of plates mounted thereon, and the collapsing of the erectors at the four corners of each of the carriers doubling as the pallets, the two steps being accomplished in a desired order; and storing the carriers doubling as the pallets into the transport container in a layered manner after the stacks of plates are removed from the pallets.
Where the pallets for stacks of plates of present invention methods are used, each pallet allows a variety of plates to be fastened, and the pallets are dimensionally standardized with respect to carriers that carry them, and this arrangement allows stacks of plates to be stored efficiently in a limited space.
Where the inventive methods are implemented, there is no need to spend long hours packing meticulously stacks of plates using large quantities of wood material as is conventionally the case. The invention makes it possible easily and efficiently to pack, load and store stacks of plates in a transport container, with huge savings obtained in the manhours required for such activities. Whereas profiles are difficult to pack by conventional methods, the invention enables stacks of profiles to be packed and fastened with ease. Because each pallet allows a variety of plates to be fastened and transported, the repeated use of a single kind of pallets can deal with diverse kinds of plates in stacks. Furthermore, with the inventive structures for storage and fastening, only small quantities of junk and scraps are produced upon unloading from the packing and fastening materials; most of the materials used for packing and fastening may be recycled for repeated use.
Because the inventive method for storage eliminates interference between stacks of plates (piled one upon another and/or arranged side by side), damage to the stored stacks is minimized in transit. The pallets are dimensionally standardized with respect to carriers that carry them, and these carriers are in turn standardized dimensionally relative to a transport container that accommodates the carriers. This arrangement allows stacks of plates to be stored efficiently in a limited space. In addition, the arrangement facilitates the loading and unloading of stacks of plates to and from the transport container.
According to the inventive method for transport, the carriers equipped with pallets having stacks of plates mounted thereon are accommodated efficiently inside each transport container. Stacks of plates in large quantities are thus transported efficiently using a limited amount of space. This feature is particularly effective where stacks of profiles such as steel plates are transported overseas.
The fastening structures according to the sixth and the fifteenth aspect of the invention, and the storing structures according to the seventh, the eighth, the sixteenth and the seventeenth aspect of the invention, are especially suited for realizing the benefits of storage and transport outlined above.
The carrier doubling as the pallet according to the tenth aspect of the invention is simply structured and comprises only a small number of component parts. Yet the inventive carrier is noted for its ability effectively to act both as a pallet and as a carrier Because the height (i.e., thickness) of this carrier is small, the occupied storage space is that much reduced. This in turn allows a large number of carriers doubling as pallets to be returned using a limited space after their charges have been unloaded.
According to the inventive method for storing pallet-equipped carriers after their charges have been removed, large numbers of pallets and carriers can be returned using a reduced amount of space. For return transport by ship, the pallets and carriers freed of their charges are fastened securely and kept safely in place until their destination is reached. This feature is especially useful for the empty pallets and carriers to be returned by truck or by ship for repeated use.
These and other objects, features and advantages of the invention will become more apparent upon a reading of the following description and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view showing three different pallets for embodying the invention;
Fig. 2 is a plan view of another pallet for embodying the invention;
Fig. 3 is a plan view of yet another pallet for embodying the invention;
Fig. 4 is a perspective view of a carrier for use with the embodiments of the invention;
Fig. 5 is a schematic view showing an erector and its surroundings of the carrier sketched in Fig. 4;
Fig. 6 is a perspective view of a carrier doubling as a pallet;
Fig. 7 is a perspective view of a pallet with a packed stack of plates fastened thereto;
Fig. 8 is a view illustrating how to wrap and pack a stack of plates with a packing sheet according to the invention;
Fig. 9 is a view sketching how to place a pallet onto the stack of plates wrapped and packed with the packing sheet according to the invention;
Fig. 10 is a view picturing how to place a pallet onto a packing sheet according to the invention;
Fig. 11 is a view indicating how a stack of plates topped with a pallet is turned upside down according to the invention;
Fig. 12 is a view showing a stack reversing machine as it has yet to be activated for the reversing action in connection with the invention;
Fig. 13 is a view depicting the stack reversing machine as it is activated for the reversing action in connection with the invention;
Fig. 14 is a view illustrating how to remove a pallet from a stack of plates after the stack is turned upside down by the stack reversing machine;
Fig. 15 is a view indicating how to attach inner dolly blocks to a stack of plates before the stack is packed with a packing sheet according to the invention;
Fig. 16 is a view showing how to pack a stack of plates with a packing sheet and then to seal the packed stack with adhesive tapes according to the invention;
Fig. 17 is a view exhibiting how to attach outer dolly blocks to a stack of plates after the stack is packed with a packing sheet according to the invention;
Fig. 18 is a view presenting how to thread hoop bands through band holes of a pallet according to the invention;
Fig. 19 is a perspective view sketching a pallet with a stack of steel plates sealed and fastened thereto;
Fig. 20 is a view portraying how a pallet loaded with a stack of steel plates is placed onto a carrier according to the invention;
Fig. 21 is a view picturing how a pallet loaded with a stack of steel plates is fastened to a carrier according to the invention;
Fig. 22 is a view showing how carriers equipped with pallets having stacks of steel plates loaded thereon are illustratively accommodated inside a container;
Fig. 23 is a view depicting how carriers equipped with empty pallets are piled one upon another to form four columns in 10 layers each;
Figures 24 to 29 illustrate a conventional way of packing steel plates
Fig. 24 is a view indicating how to place a top plate onto a stack of plates strapped with a provisional band;
Fig. 25 is a view illustrating how a packing sheet is placed onto a wooden skid and then topped with a stack of plates with its provisional band and its top plate removed therefrom;
Fig. 26 is a view presenting how to attach dolly blocks to the corners of a packed stack of plates;
Fig. 27 is a view sketching how to add side plates onto the corner dolly blocks of the packed stack of plates;
Fig. 28 is a view showing how to place traverse battens on the packed stack of plates and how to strap these battens with hoop bands; and
Fig. 29 is a perspective view of the conventionally packed stack of plates.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the invention will now be described with reference to the accompanying drawings.

(1) Pallet structure

Fig. 1 shows three typical pallets for embodying the invention. The three pallets 1a, 1b and 1c in the figure have a full-size, two-thirds and one-third of the size of a carrier (module), respectively. The plane figure of the carrier is substantially equal in size to a single pallet 1a, to the combination of one pallet 1b and one pallet 1c, or to the combination of three pallets 1c.
As illustrated, these pallets each have a plurality of holes through which to thread hoop bands to fasten stacks of steel plates (called band holes 11). The band holes 11 are made in appropriate positions outlining peripherally the different plane figures of a plurality of different plates to be stacked on the pallet. That is, any of different kinds of plates may be selected, stacked and fastened on a single pallet. Illustratively, the three pallets 1a, 1b and 1c are general-purpose pallets capable of accommodating stacked steel plates of up to 17 different plane figures. In Fig. 1, reference numeral 12 represents a carrier fastening bolt hole. The full-size pallet 1a has four bolt holes 12 on its surface and another four on the back near the edges. The pallet 1a is thus fastened at these four points. On their surface and on their back, the two-third and one- third size pallets 1b and 1c each have two bolt holes 12 positioned diagonally opposite to each other near the edges where notches 15 are located. The pallets 1b and 1c are thus fastened at the two points each. Alternatively, the pallets 1b and 1c may each be fastened at four points made with no notches furnished (or at three points with one notch provided). Instead of being fastened at the four points, the pallet 1a may be secured at two, three, or at more than four points. The notches 15 are furnished to facilitate tightening work on the bolts and nuts. Any of the pallets 1a, 1b and 1c may have bolt holes 12 made on both the face and the back side thereof. This allows any one of the two sides of each pallet to be used for fastening a stack of steel plates. Where band holes 11 are not formed on the back side of the pallet, appropriate band holes may be furnished later on the back. This also allows the back side of the pallet to fasten a stack of steel plates.
The pallet surface on which to place a stack of steel plates is rid of all local bumps or welding distortion so as to prevent damage to the stacked steel plates. On the back side of the pallet are positioning holes with which to secure a carrier. Reference numeral 13 in Fig. 1 denotes a hole that accommodates the fork tips of a forklift truck for loading, moving and unloading.
Fig. 2 illustrates another example of the two-third size pallet 1b. This pallet has a plurality of fastening holes 11a with which to fasten a stack of steel plates 4a. The pallet 1b also has a plurality of fastening holes 11b with which to fasten another stack of steel plates 4b, as well as a plurality of fastening holes 11c with which to fasten yet another stack of steel plates. In Fig. 2, reference numeral 12 is a carrier fastening bolt hole; 15 is a notch; and 14 is a positioning hole with which to fasten a carrier The positioning holes 14 are used to secure the carrier where a stack of steel plates is loaded and fastened onto the back side of the pallet 1b. Similar positioning holes with which to fasten a carrier are also provided on the back side o the pallet 1b.
Fig. 3 shows another example of the one-third size pallet 1c. This pallet has 20 fastening holes 11 of various kinds with which to fasten illustratively five kinds of stacked steel profiles 4a, 4b, 4c, 4d and 4e.

(2) Carrier structure

Fig. 4 shows an example of the carrier 2 for embodying the invention. The length of the carrier in its loading and unloading direction (i.e., longitudinal dimension or depth) is a quarter (one-fourth) of the length of the container in the loading and unloading direction of the latter. The carrier 2 has a traverse dimension slightly shorter than the corresponding inner size of the container. When four carriers 2 are arranged into a longitudinal row, they are substantially equal in size to the plane figure of the container. A total of eight carriers are piled into two layers making up four columns in a single container, each carrier being loaded with a stack of steel plates. As shown in Figs. 4 and 5, the carrier 2 has inwardly collapsible erectors 21 at its four corners. The erectors when erected allow stacks of steel plates to be piled one upon another. In Fig. 5, reference numeral 20 stands for a pin and 23 for a groove. When the erector 21 is raised upward, the erector 21 is relocated so that the washer 22 reaches the topmost position of the groove 23. The action allows the erector 21 to be collapsed rightward as seen in Fig. 5. Reference numeral 24 is a hole that accommodates the top of an erector attached to another carrier 2. With the erector tops inserted in the holes 24, the carriers 2 are piled one upon another in a securely layered manner.
When the carriers are piled one upon another with their erectors 21 extended, there occurs no interference between the stacks of steel plates carried by the stacked carriers. This prevents damage to the stacks of plates in transit, thus keeping them in good quality. Legs 28 at two edges of the carriers prevent the top plates of the pallets from getting into contact with one another when the emptied carriers together with the pallets are piled in a layered manner as shown in Fig. 23 for return haulage. When piled up as shown in Fig. 23, up to 40 sets of carriers and pallets may be stored in a 20-foot container. In Fig. 4, reference numeral 25 indicates a positioning projection with which to position a pallet easily. The projections 25 eliminate the need for the conventional tedious task of positioning the pallet as it is being fastened to a carrier. Pallet fastening bolt holes 26 are spaced equally apart in the longitudinal direction of the carrier. The bolt holes 26 are arranged so as to address possible future changes in the pallet dimensions. Illustratively, the bolt hole spacing will accommodate pallets of one-half size, one-fourth size (plus two-fourth and three-fourth sizes by extension), and one-fifth size (as well as two-fifth, three-fifth and four-fifth sizes by extension). In Fig. 4, reference numeral 27 is a hole that accommodates the fork tips of a forklift truck for loading, moving and unloading.

(3) Methods for packing stacks of steel plates, storing the stacks into a container and transporting the container

Below is a description of the inventive methods headlined above with reference to Figs. 8 through 23. As shown in Fig. 8, numerous steel profiles are first stacked on a pallet 87 that may be moved about by forklift. The stack of steel profiles is then covered with a packing sheet 7 from above. The packing sheet 7 is illustratively a transparent plastic resin sheet coated with rust preventives. With the stack of steel profiles packed with the packing sheet 7, a pallet 1a (shown in Fig. 1) is positioned and set on the packed stack using a crane or forklift (Figs. 9 and 10).
The stack of steel profiles thus packed with the packing sheet and topped with the pallet is then placed on a base 101 of a stack reversing machine 10 shown in Fig. 12.
With pressure arms 102a and 102b processed and pressed appropriately with respect to the stack of steel plates, the stack reversing machine 10 is activated (Figs. 12 and 13). The reversing action produces an assembly of the pallet 1, the packing sheet 7, the stack of steel plates 4 and the pallet 87 being piled up (Fig. 11). Thereafter, the pallet 87 is removed from the stack of steel plates 4 (Fig. 14). Inner dolly blocks 88 are attached to those positions of the stack which are to be strapped with hoop bands (Fig. 15); the blocks 88 are meant to prevent friction between the stack of steel plate and the packing sheet when the hoop bands are strapped. After the stack of steel plates is packed with another packing sheet, the packed stack is sealed with adhesive tapes (Fig. 16).
In addition, outer dolly blocks are attached to those positions of the stack which are to be strapped with hoop bands (Fig. 17). Traverse battens 82 are laid across the opposite dolly blocks 81, and hoop bands 3 are threaded through the appropriately located band holes of the pallet (Fig. 18). The sealing positions are tightened and sealed by sealer using L-shaped fittings. This produces a pallet assembly composed of the stack of steel plates packed, fastened and sealed on the pallet (Fig. 19). Fig. 7 shows another example of the similar pallet assembly 8 comprising a stack of steel plates. Unlike what is shown in Fig. 19, the plane figure of the stacked steel plates in Fig. 7 is a trapezoid. In Fig. 7, reference numeral 83 stands for an overlap seal, 84 for a seal guard, 85 for a carton tape, and 86 for a tag.
The pallet assembly 8 (see Figure 19) composed of the plate stack is then placed on a carrier 2 and positioned so that alignment holes, not shown, on the back side of the pallet 1 will be engaged with the positioning projection 25 of the carrier 2 (Fig. 20). With the pallet assembly 8 positioned, bolts and nuts 22 are used to fasten the pallet assembly 8 to the carrier 2. This produces a carrier assembly 9 composed of the pallet and the plate stack (Figs. 20 and 21). There are four fastening positions, two each on the right and on the left (Figs. 20 and 21). If the pallet is smaller, a total of two fastening positions may be enough. The number and the locational arrangement of fastening positions are not limited to those described above; they may be changed as desired.
Thereafter, each carrier assembly 9 composed of the pallet and the plate stack is stored into a container 5 (Fig. 22). In this example, the container 5 accommodates, from back to front, carrier assemblies 9a through 9e composed of stacks of various steel profiles 4a through 4e packed and fastened. During loading of the carrier assemblies 9a through 9e, care should be exercised to ascertain that the loads are distributed in a substantially uniform manner throughout the interior of the container 5. After the first layer of the carriers has been loaded, the erectors 21 of each carrier are extended so that another layer of the carriers 9 combining pallets and steel plate stacks will be piled on top. In this example, in view of the available container space and the product weight, two layers of the pallet-equipped carriers loaded with the stacked steel plates are stored in the container 5.
The container 5 containing the stacks of steel plates 4 is transported illustratively by truck and then on board a container ship for an overseas (or domestic) destination. Where maritime transport is not necessary, the container 5 may be transported throughout by truck or by rail until the destination, be it domestic or foreign, is reached.

(4) Methods for unloading stacks of steel plates from the container, unpacking the stacks and returning empty pallets and carriers

The inventive methods outlined above are practiced by effectively reversing the steps constituting the methods described in (3) earlier, "the methods for packing stacks of steel plates, storing the stacks into a container and transporting the container."
Of the two layers in the container comprising the carrier assemblies 9a through 9e composed of the pallets and the stacks of steel plates, the top layer is first unloaded by forklift After removal of the first layer of the carriers 9 equipped with the pallets having the steel plates stacked thereon, the erectors of the carriers constituting the bottom layer are folded. With all carriers taken out of the container, the bolts and nuts fastening the pallets to the carriers are removed. The pallets still loaded with their stacked steel plates are moved either onto appropriate product shelves for storage or to the site of manufacture for imminent use. The empty carriers and the bolts and nuts are held in temporary custody, to be returned for another use.
Each pallet with the stack of steel plates fastened thereon is unpacked as follows: the hoop bands are first cut and removed. With the hoop bands removed, the battens, seal guards and outer dolly blocks are taken off. After the adhesive tapes are peeled off the packing sheet, the sheet is unfolded. Then with the inner dolly blocks removed, a suitable pallet (e.g., pallet 87 of Fig. 8) is prepared on site and placed on top of the stack of steel plates. The plate stack with the pallet placed on top is set on the stack reversing machine. After the assembly of the pallet and plate stack is turned upside down by the stack reversing machine, the pallet 1a is removed. At this point, the pallet 1a is empty and ready to be returned. With the packing paper removed, the stack of steel plates is bared for use (i.e., the same as the stack of Fig. 8) on the pallet prepared on site.
Thereafter, the empty pallet 1 is fastened with bolts and nuts to the empty carrier 2. Each empty carrier equipped with the corresponding empty pallet (the assembly may be called a set) is loaded into a container. (This container may be the one which brought the stacks of steel plates to their destination). In this example, up to 10 sets may be piled up in a single column. In a 20-foot container, up to 40 sets (in 4 columns) may be loaded (Fig. 23). In handling and moving about the sets, the forklift truck inserts its fork tips into the fork tip holes of the pallets.
The container thus loaded with the empty carriers and pallets is returned by truck, by ship or by other suitable means to the destination (e.g., the depot from which the container was originated). When returned, the pallets, carriers, bolts and nuts are recycled for another use.

(5) Effects of the embodiments

The invention when embodied as described offers the following major benefits:

(1) Unlike conventional methods, there is no need to spend long hours packing and fastening meticulously stacks of plates using large quantities of wood material. The invention makes it possible easily and efficiently to pack, load and store the plate stacks in a transport container, with huge savings obtained in the manhours required for such activities. In experiments conducted by the inventors, whereas the conventional methods required two workers working 240 hours to pack and fasten a given amount of plate stacks, the inventive methods allowed one worker working only 30 minutes to accomplish the same task.
(2) While profiles are difficult to pack by conventional methods, the invention enables stacks of steel profiles to be packed and fastened with ease. Because each pallet allows a variety of plates to be fastened thereto and transported thereby, the repeated use of a single kind of pallets can handle diverse kinds of stacked steel plates.
(3) Only small quantities of junk and scraps are produced upon unloading from the packing and fastening materials. Most of the materials used for packing and fastening may be recycled for repeated use.
(4) Because the invention eliminates interference between stacks of steel plates (piled one upon another and/or arranged side by side), damage to the stored stacks is minimized in transit.
(5) The invention makes it easier to load and unload the stacks of steel plates to and from the container.
(6) According to the invention, the pallets are dimensionally standardized with respect to carriers that carry them, and these carriers are in turn standardized dimensionally relative to a transport container that accommodates the carriers. This arrangement allows stacks of plates to be stored efficiently in a limited space. It is easy to fasten stacks of steel plates to pallets and the stack-loaded pallets to the carriers. The carrier assemblies composed of the pallets and the plate stacks are loaded just as easily into the container. The manhours for accomplishing these tasks are reduced appreciably. Stacks of plates in quantities are thus transported efficiently. This feature is particularly effective where stacks of steel profiles are to be transported overseas in containers.
(7) The packing sheet is a transparent or translucent sheet coated with volatile corrosion inhibitor (VCI). The sheet allows what is wrapped inside to be seen through. This makes it possible to inspect from the outside the packed stacks of steel plates for correction and other irregularities.
(8) According to the invention, the pallets, the pallet assemblies composed of stacks of steel plates, and the carrier assemblies composed of the pallets together with the stacks of steel plates, are all furnished with holes that accommodate the fork tips of the forklift truck.

The structure allows these packages to be readily handled and moved about by forklift.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. For example, the plane figures, sizes and thicknesses of plates as well as the number of stacked plates may be changed as desired. The shapes, sizes and thicknesses of the pallets may also vary provided these characteristics allow the pallets to be mounted and fastened onto the carriers in use. The band holes of the pallets may vary in size, shape and number as long as these holes can be used to fasten the necessary stacks of plates. A single pallet may have any desired varieties of profiles mounted and fastened thereon. The greater the number of profile types accommodated on a single pallet, the more useful the pallet is for repeated use. However, it should be noted that too many band holes made on the pallet may reduce its strength. In one embodiment of the invention, only one side of each pallet (e.g., the face side alone) has band holes. Alternatively, both the face and the back side of the pallet may have band holes furnished thereon. The alternative band hole arrangement allows each pallet to be used for a wider range of applications and thus enhances its usefulness.
The bolts and nuts are not the only means for fastening each pallet to the carrier. Alternatively, the pallet-and-carrier combination may be secured through the use of a pair of alignment projections and depressions appropriately positioned on the two components. The pallet may have the depressions and the carrier the projections, or the pallet may have the projections and the carrier the depressions. Other fastening or engaging means may also be used to keep the pallet and carrier fastened in place.
The shape and size of each carrier may vary as long as these characteristics allow a single carrier or a plurality of carriers to be stored snugly in a transport container (the multiple carriers may be arranged crosswise, lengthwise, or both crosswise and lengthwise inside the container). As described earlier, each of the carriers should preferably have the length composed of any of a plurality of unit lengths equally dividing the length of the transport container in its loading and unloading direction alone. (In other words, the width of each carrier is substantially the same as that of the container.)
Preferably, the carrier length is a unit length such that the length of the container becomes an integer multiple of that unit (one-third size, one-half size, one-fifth size, one-sixth size, etc. in addition to the one-quarter size of the container described earlier). These sizes are not limitative of the invention. Illustratively, a two-fifth size carrier and a three-fifth size carrier may be combined to match the container size. The combination may also be one of a one-sixth and a five-sixth size carrier, or may be one including a two-seventh, three-seventh, four-seventh and five-seventh size carriers Inside the container, the carriers may be arranged to have unit lengths constituting the full container size only crosswise, or both crosswise and lengthwise, with respect to the loading and unloading direction of the container. The carriers may vary in size and plane figure as long as they correspond substantially in size and plane figure to the whole container when combined and loaded into the latter. The carriers combined to constitute the full container size in the crosswise direction alone are suitable for being loaded and unloaded to and from a shallow-depth container; the carriers constituting the full container size both crosswise and lengthwise are suitable for use with a large container extending crosswise and lengthwise.
The discrete carriers and the carriers doubling as pallets mentioned in the earlier description are arranged to have erectors. Alternatively, the carriers may be rid of these erectors as a reference example. Such erector-free carriers may still be used effectively for single-tier haulage. Instead of the erectors, the carriers may each be equipped peripherally with an appropriate frame, partitions or wall-like members illustratively having a rectangular cross-section of a character E minus the middle bar. These fittings also allow the carriers to be stacked in layers without causing interference between the stacks of plates piled one upon another.
The sheet-like packing material is not limited to the above-mentioned transparent or translucent plastic resin sheet coated with rust preventives. Alternatively, the packing material may be composed of a commonly used polyethylene cloth sheet and of the sheet coated with volatile corrosion inhibitor (VCI). Suitable packing sheets of other compositions may also be used.
Although the container used for transport is not limited in size or in plane figure, the container is generally of a rectangular box type as described above. The products are usually loaded and unloaded to and from the container through its rear opening. Alternatively, as implied above, the container may be opened sideways.
Fig. 6 shows a typical carrier 6 doubling as a pallet according to the invention. This carrier comprises a base 61 having effectively the same structure as that of the above-described carriers, the surface (and/or the back side) of the carrier being furnished with band holes. (These band holes provide effectively the same function as that of the band holes described above.) The shapes, sizes and number of these band holes may vary depending on the purpose and use of the carrier doubling as the pallet. The structure and shape of the erectors attached to the carrier may also be changed as needed.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.

Claims

A structure comprising a pallet (1) adapted for fastening stacks of plates (4), the pallet defining a plurality of apertures in appropriate positions peripheral to outer edges of a plurality of different plates to be stacked on said pallet, said apertures being suitable for receiving fasteners (3) for selectively fastening a given stack of plates, a stack of plates (4) disposed approximately within the geometry formed by an appropriate number of apertures for receiving fasteners for fastening the stack to the pallet, and a plurality of fasteners threaded through said appropriate number of apertures so as to fasten said stack of plates to said pallet, characterised in that the apertures are holes (11) in the pallet and the fasteners (3) are threaded through the said holes (11).
A structure according to claim 1 which has a periphery substantially corresponding to that of a carrier adapted for receiving the pallet, or which can be placed adjacent other such pallets so as to produce a combination of pallets having a periphery substantially corresponding to that of a carrier for carrying said combination of pallets.
A method comprising the steps of:
providing a pallet as specified in claim 1;

positioning a stack comprising a plurality of different plates on the pallet with holes defined by the pallet being peripheral to outer edges of said plates;

threading a plurality of fasteners through appropriate holes of the pallet so as to fasten said stack of plates to said pallet;

fastening said pallet together with said stack of plates to a carrier having inwardly collapsible erectors mounted on four corners thereof, said erectors allowing a plurality of pallets along with the stacks of plates to be piled one upon another in a layered manner, the carrier having a periphery defining an area substantially corresponding to the periphery of the pallet or of a combination of such pallets adjacent to one another;

storing the carrier together with the pallet into a transport container, the transport container having a periphery corresponding substantially to the periphery of the carrier or of a combination of such carriers adjacent to one another;

erecting said erectors of the carrier to support on top thereof another pallet with a stack of plates fastened thereto.
A method according to claim 3 further comprising the steps of:
placing a sheet-like packing material over a given stack of plates;

positioning and setting a pallet where appropriate on top of said sheet-like packing material;

turning upside down the assembly of said stack of plates, of said sheet-like packing material and of said pallet; and

folding any part of said sheet-like packing material left out of said stack of plates so as to wrap and pack said stack on said pallet.
A method comprising the step of transporting the stacks of plates resulting from the method of claim 3 or claim 4, said stacks being loaded onto pallets which in turn are mounted on carriers as defined in claim 2 or claim 3.
A method for packing and fastening stacks of plates, comprising the steps of:
placing a sheet-like packing material over a given stack of plates having different peripheries;

positioning and setting a pallet where appropriate on top of said sheet-like packing material, said pallet defining a plurality of holes in appropriate positions which are peripheral to outer edges of the different plates, said holes being used selectively to receive fasteners which can be used to fasten any of the stacked plates;

turning upside down the assembly of said stack of plates, of said sheet-like packing material and of said pallet;

folding any part of said sheet-like packing material left out of said stack of plates so as to wrap and pack said stack; and

threading a plurality of fasteners through said holes so as to fasten the packed stack of plates to said pallet.
A structure according to claim 1 or claim 2 comprising:
said pallet loaded with said stack of plates; and

a carrier to which said pallet is fastened and which has inwardly collapsible erectors mounted on four corners thereof, said erectors allowing a plurality of the pallets along with the stacks of plates to be piled one upon another in a layered manner.
A structure comprising:
a transport container; and

a plurality of carriers which may be piled one upon another in a layered manner inside said transport container and which carry pallets with stacks of plates loaded and fastened thereon to give structures as claimed in claim 7;
wherein the periphery of the carrier or of a combination of such carriers constituting one layer is substantially equal to the periphery of said transport container; and
wherein the periphery of either one pallet or of a combination of pallets constituting one layer is substantially equal to the periphery of each carrier.
A structure according to claim 8 wherein the transport container is adapted to accommodate a whole number of carriers and pallets along the length of the container.
A method for storing pallet bearing carriers with stacks of plates removed therefrom, comprising the steps of:
unloading from a structure according to claim 8 or claim 9 carriers carrying pallets with stacks of plates mounted thereon;

removing from said carriers the pallets with the stacks of plates mounted thereon, and collapsing erectors at the four corners of each of said carriers (if present);

fastening said pallets to said carriers after said stacks of plates are removed from said pallets; and

storing the resultant pallet bearing carriers in said transport container in a layered manner.
A structure comprising a carrier (2) which also functions as a pallet, defining:
a plurality of apertures in appropriate positions peripheral to outside edges of any of a plurality of different plates (4) in a stack to be stacked on the carrier, said apertures being suitable for receiving fasteners (3) for selectively fastening any of the stacked plates to the carrier;

a stack of plates disposed approximately within the geometry formed by an appropriate number of apertures defined by said carrier for receiving fasteners for fastening to the carrier; and

a plurality of fasteners located in the said appropriate number of apertures so as to fasten said stack of plates to said carriers, characterised in that the apertures are holes (11) in the carrier and the fasteners (3) are threaded through the said holes (11), and in that inwardly collapsible erectors (21) are mounted on four corners of the carrier (2), said erectors allowing a plurality of stacks of plates to be piled one upon another in a layered manner.
A method for storing stacks of plates, comprising the steps of:
disposing a stack of plates where appropriate on a carrier which also functions as a pallet, as defined in claim 11;

threading a plurality of fasteners through said holes of said carrier so as to fasten said stack of plates to said carrier;

storing in a transport container said carrier with said stack of plates fastened thereto, the periphery of the carrier or of a combination of such carriers adjacent to one another being substantially equal to the periphery of said transport container; and

erecting said erectors of each carrier to support on top thereof another such carrier with a stack of plates fastened thereto.
A method for storing stacks of plates according to claim 12, further comprising the steps of:
placing a sheet-like packing material over a given stack of plates;

positioning and setting said carrier where appropriate on top of said sheet-like packing material;

turning upside down the assembly of said stack of plates, of said sheet-like packing material and of said carrier; and

folding any part of said sheet-like packing material left out of said stack of plates so as to wrap and pack said stack on said carrier.
A method for transporting stacks of plates, comprising the step of transporting the carriers storing stacks of plates as defined in claim 12 or claim 13.
A method for packing and fastening stacks of plates, comprising the steps of:
placing a sheet-like packing material over a given stack of plates having different peripheries;

positioning and setting a carrier as defined in claim 11, where appropriate on top of said sheet-like packing material, in such a manner so that the erectors of said carrier will be located downwardly;

turning upside down the assembly of said stack of plates, of said sheet-like packing material and of said carrier;

folding any part of said sheet-like packing material left out of said stack of plates so as to wrap and pack said stack; and

threading a plurality of fasteners through said holes of the carrier so as to fasten the packed stack of plates to said carrier.
A structure according to claim 11 wherein the periphery of the carrier or of a combination of such carriers adjacent one another constituting one layer is substantially equal to the periphery of the transport container.
A structure according to claim 16, wherein the container is adapted to accommodate a whole number of carriers along the length of the container.
A method comprising the steps of:
unloading carriers from a structure according to claim 16 or 17;

removing from said carriers the stacks of plates mounted thereon, and collapsing the erectors at the four corners of each of said carriers; and

storing said carriers in said transport container in a layered manner after said stacks of plates are removed from them.