US20230322437A1

US20230322437A1 - Transport container

Info

Publication number: US20230322437A1
Application number: US17/716,857
Authority: US
Inventors: Luke Phelps; Philip Schwarz; Steven Kottwitz; Ethan Wollbrink
Original assignee: Pvpallet Inc
Current assignee: Pvpallet Inc
Priority date: 2022-04-08
Filing date: 2022-04-08
Publication date: 2023-10-12

Abstract

A transport container for carrying one or more generally planar objects having a base configured to support the one or more generally planar objects. First and second side walls are removably coupled to opposing ends of the base. The first and second side walls are movable substantially along a first axis between an extended position and a contracted position. The first side wall is spaced from the second side wall by a first distance when the first and second side walls are in the extended position and by a second distance when the first and second side walls are in the contracted position. The first and second side walls are movable substantially along a second axis between a deployed position and a collapsed position. The first and second side walls have a first height in the deployed position and a second height different than the first height in the collapsed position.

Description

FIELD OF THE DISCLOSURE

The present disclosure generally relates to transport containers and, more particularly, to transport containers for planar objects, such as solar or photovoltaic (PV) panels.

BACKGROUND OF THE DISCLOSURE

Planar objects, like solar panels, may be stored or shipped in various containers. For example, such objects may be stacked together, strapped on a shipping pallet, and shipped to an installation site. At least some known containers do not adequately protect solar panels inside the container during storage or transit. As a result, the solar panels may become scratched, bent, or broken, causing additional costs and delays in installation while replacement solar panels are sent to the job site.
Additionally, on various job sites, the solar panels are removed from the container as they are needed. However, because the solar panels are staked or arranged from one end of the container to the other, as solar panels are removed from at least some known containers, the remaining panels can fall or slip down the container side wall, which may result in scratching or damaging the panel surface.

SUMMARY OF THE DISCLOSURE

In one aspect, a transport container for carrying one or more generally planar objects comprises a base configured to support the one or more generally planar objects. First and second side walls are removably coupled to opposing ends of the base. The first and second side walls are movable substantially along a first axis between an extended position and a contracted position. The first side wall is spaced from the second side wall by a first distance when the first and second side walls are in the extended position and by a second distance when the first and second side walls are in the contracted position. The second distance is different from the first distance. The first and second side walls are movable substantially along a second axis between a deployed position and a collapsed position. The first and second side walls have a first height in the deployed position and a second height different than the first height in the collapsed position.
In another aspect, a transport container for carrying one or more generally planar objects comprises a base configured to support the one or more generally planar objects. The base defines two or more discrete positions along a first axis. A first side wall is supported by the base. A second side wall is moveable between the two or more discrete positions to be selectively supported at one of the two or more discrete positions in order to change a distance between the first and second side walls to conform the distance to a dimension of the one or more generally planar objects. The first and second side walls are movable substantially along a second axis between a deployed position and a collapsed position. In the deployed position, the first and second side walls are substantially upright. In the collapsed position, the first and second side walls lay substantially flat on the base.
In another aspect, a method of conforming a transport container that carries one or more generally planar objects to a dimension of the one or more generally planar objects comprises moving first and second side walls from a collapsed position in which the first and second side walls lie substantially flat on a base to a deployed position in which the first and second side walls are substantially upright and are supported by the base. The method further includes removing one or both of the first and second side walls from a first position on the base and reattaching said one or both of the first and second side walls at a second position on the base different than the first position such that a distance between the first and second side walls conforms to the dimension of the one or more generally planar objects.
Other objects and features of the disclosure with be in part apparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a transport container of the present disclosure, with side walls of the transport container in an extended position;

FIG. 2 is a perspective view of the transport container, with the first and second side walls in a contracted position;

FIG. 3 is an upper perspective view of a base of the transport container;

FIG. 4 is a lower perspective view of the base;

FIG. 5 is a front side perspective view of one of the side walls of the transport container;

FIG. 6 is a back side perspective view of the side wall;

FIG. 7 is a detailed front side view showing the connection of the side wall to the base;

FIG. 8 is a partially exploded view of the transport container;

FIG. 9 is a detailed front side view of the side wall spaced apart from the base, with a brace of the side wall hidden from view;

FIG. 10 is a front side perspective view of a brace of the transport container;

FIG. 11 is a rear side perspective view of the brace;

FIG. 12 is detailed perspective view showing the engagement of the brace with the base;

FIG. 13 is a detailed cross-sectional view of the engagement of the brace with the base;

FIG. 14 is a detailed perspective view of the brace attached to the side wall;

FIG. 15 is a front side perspective view of a retainer of the transport container;

FIG. 16 is a rear side perspective view of the retainer;

FIG. 17 is a perspective view of the transport container with the first and second side wall sin a collapsed position;

FIG. 18 is an enlarged view of FIG. 17 ;

FIG. 19 is a cross-sectional view taken through line 19-19 of FIG. 17 ;

FIG. 20 is an enlarged view of FIG. 18 ;

FIG. 21 is a partially exploded perspective view of ramps and the base of the transport container.

Corresponding reference characters indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure generally relates to a transport container and, more particularly, to a transport container for planar objects, such as solar or photovoltaic (PV) panels. The transport container described herein can be expanded to fit different sizes of solar panels. The transport container includes side walls to adequately protect the solar panels and supports to prevent the solar panels from falling. The transport container can be collapsed for convenient storage after the solar panels have been unloaded from the container. It is understood the transport container can be used to support and transport other objects, besides solar panels.
Referring to FIGS. 1-4 , one example of a transport container or pallet constructed according to the teachings of the present disclosure is generally indicated at reference numeral 10. The transport container 10 may be used to carry and transport one or more objects O. In particular, the transport container 10 may be used to carry one or more generally planar objects O, such as panels, sheets, boards, etc. In some examples, the objects O are solar panels (e.g., panels). However, it is understood the transport container 10 may be used to transport objects O of generally any size and shape.
The transport container 10 includes a platform or base 12 (broadly, base assembly) and opposing first and second side walls 14, 16 (e.g., first and second side wall assemblies) supported by the base 12. The first and second side walls 14, 16 are removably connected or coupled opposing ends (broadly, end portions) of the base 12. FIGS. 1 and 2 show the first and second side walls 14, 16 in a deployed position. In the deployed position, the first and second side wall 14, 16 are erected on the base 12. The first and second side walls 14, 16 may be moved to a collapsed position, shown in FIG. 17 . In the collapsed position, the first and second side walls 14, 16 lay flat on the base 12. The base 12 is configured to support the one or more generally planar objects O. The base 12 includes an upper surface 18 (shown in FIG. 3 ) configured to engage and support the one or more generally planar objects O and an opposing lower surface 20 (shown in FIG. 4 ). The base 12 has opposing first and second ends 22, 24 with a first or longitudinal axis LA extending between the first and second ends 22, 24. The base 12 includes opposite first and second rails 29, 31 that are generally parallel to the longitudinal axis LA. The first rail 29 extends along the first side of the base 12 between the first and second end 22, 24 and the second rail 31 extends along the second side of the base 12 between the first and second ends 22, 24. The first and second rails 29, 31 extend upward from the upper surface 18. The first and second rails 29, 31 help keep the planar objects O on the base 12.
The base 12 may define one or more forklift channels 23. Each forklift channel 23 may be sized and shaped, for example, to receive a fork or tine of a forklift, a pallet jack, or other suitable lifting device (not shown) to enable the lifting device to lift and move the transport container 10. In the illustrated embodiment, each forklift channel 23 extends generally perpendicular (e.g., laterally) to the longitudinal axis LA. Alternatively, one or more forklift channels 23 may extend in any other direction that enables the transport container 10 to function as described herein.
The base 12 may include one or more reinforcing members 25 for strengthening the base 12 and enabling the transport container 10 to carry heavier loads. The one or more reinforcing members 25 extend between first end 22 and second end 24. The one or more reinforcing members extend generally parallel to the longitudinal axis LA. The base 12 (e.g., a platform thereof) includes one or more reinforcing channels extending in or through the base 12, each reinforcing channel sized and shaped to receive one of the reinforcing members 25. The base 12 includes end caps 27 at each end of the reinforcing channel, closing an end of the reinforcing channel to secure the reinforcing member 25 therein. The reinforcing members 25 facilitate the transfer of loads from the ends of the base 12 to or toward the middle of the base 12 to where the forklift channels 23 are located. This ensures that when the base 12 is picked up by the forks of a forklift, the base 12, via the reinforcing members 25, can carry the load of the objects O supported thereon and does not collapse under the weight of the objects O. The base 12 may be of a sufficient length that the reinforcing members 25 are necessary to ensure the ends 22, 24 of the base 12 are sufficiently supported and can carry the load of the objects O when the base 12 is picked up, such as by a forklift. In some examples, the base 12 (and side walls 14, 16) is made of plastic (e.g., molded plastic) and the reinforcing members 25 are made of metal. For example, the reinforcing members 25 may be steel members such as rods, bars, square tubing, circular tubing, etc. In some examples, the reinforcing members 25 in the base 12 are pre-stressed, further strengthening the base 12. In some examples, the transport container 10 (e.g., base 12) with the reinforcement members 25 can carry up to about 2,700 pounds (about 1,225 kilograms).
In one method of assembly, the reinforcing channels of the base 12 are constructed to be curved (e.g., about an axis that is generally parallel to the upper or lower surface 18, 20 and generally perpendicular to the longitudinal axis LA). To insert the reinforcing member 25 into the reinforcing channel, the base 12 is bent to substantially straighten the curved reinforcing channel to permit the reinforcing member 25 to be inserted (e.g., slid) into the channel through the open end. In one example, the base 12 is bent or deflected about 1-1.5 inches (about 2.5-3.8 centimeters). After the reinforcing member 25 is inserted into the reinforcing channel, the tool bending the base 12 is released, allowing the base 12 to return to its unbent or undeflected state. As the base 12 returns to the to its undeflected state, material of the base 12 stresses (e.g., bends) the reinforcing member 25 (e.g., the reinforcing member 25 becomes pre-stressed before a load is placed on the base 12). In some examples, the reinforcing member 25 is inserted into the reinforcing channel after (e.g., immediately after) the base 12 exits an injection molding machine (e.g., while the base 12 is warm), making it easier to bend the base 12. Further, inserting the reinforcement member 25 while the base 12 is still cooling down from the molding process, results in the plastic material of the base 12 constricting around the reinforcing member 25 as the plastic material cools, further securing the reinforcing member to the base 12.
The size of the transport container 10 is selectively configurable to fit the size and shape of the one or more objects O the transport container 10 is carrying. In particular, a width of the transport container 10 (e.g., a distance between the first and second side walls 14, 16) is selectively adjustable to fit a dimension, such as the width, length or height, of the one or more objects O. Broadly, at least one of the first and second side walls 14, 16 is movable relative to the other of the first and second side wall 14, 16 (and relative to the base 12) to change a distance (e.g., width) between the first and second side walls 14, 16 to conform or match the distance to a dimension (e.g., length) of the one or more objects O. In the illustrated embodiment, both the first and second side walls 14, 16 are movable.
The first and second side walls 14, 16 may be moved between an extended position (generally shown in FIG. 1 ) and a contracted position (generally shown in FIG. 2 ). Broadly, the extended and contracted positions are different (e.g., first and second) longitudinal positions, with the extended position being any position outward of a contracted position. To move between the extended and contracted positions, the first and second side walls 14, 16 move substantially along the longitudinal axis LA. The first side wall 14 is spaced from the second side wall 16 by a first distance D1 (shown in FIG. 1 ) when the first and second side walls 14, 16 are in the extended position and by a second distance D2 (shown in FIG. 2 ) when the first and second side walls 14, 16 are in the contracted position. The second distance D2 is different than the first distance D1. In the illustrated embodiment, the second distance D2 is less than the first distance D1. In other embodiments or methods of use, the second distance D2 may be more than the first distance D1. The first distance D1 is the maximum distance the first and second side walls 14, 16 can be separated when coupled to the base 12 and the second distance D2 is the minimum distance the first and second side walls 14, 16 can be separated when coupled the base 12. The first and second side walls 14, 16 are selectively movable to a plurality of different longitudinal positions and, thus, other distances are possible (e.g., a third distance, a fourth distance, etc.). For example, the first and second side walls 14, 16 are movable between a plurality of different positions (e.g., a plurality of intermediate positions) between the contracted and extended positions, and thereby have a plurality of different distances. In this manner, the transport container 10 may be arranged to fit the size or dimension of a plurality of different objects O. Moreover, by arranging the transport container 10 to conform or fit the size of the objects O supported thereon, the transport container 10 may better protect and carry the objects.
In the illustrated embodiment, each of the first and second side walls 214, 216 are removably couplable to the base 12 in one of the contracted position or the extended position (broadly, a plurality of different positions). The first and second side walls 14, 16 move in opposite directions when moving between the extended position and the contracted position. For example, the first and second side walls 14, 16 move outward (e.g., away from the center of the base 12) along or parallel to the longitudinal axis LA to increase the distance between the first and second side walls 14, 16. In another example, the first and second side walls 14, 16 move inward (e.g., toward the center of the base 12) along or parallel to the longitudinal axis LA to decrease the distance between the first and second side walls 14, 16. In some examples, the first and second side walls 14, 16 move outward toward the extended position (e.g., to the first distance D1) from the contracted position and move inward toward the contracted position (e.g., to the second distance D2) from the extended position. The first and second side walls 14, 16 are independently movable relative to each other. For example, the first side wall 14 can move between the extended and contracted positions while the second side wall 16 remains in place.
Referring to FIGS. 5-9 , in the illustrated embodiment, the first and second side walls 14, 16 are similar or generally identical to each other (e.g., the first and second side walls 14, 16 are mirror images of each other). Accordingly, the first side wall 14 will be described in further detail herein with the understanding that the second side wall 16 has essentially a similar or the same construction. Thus, descriptions regarding the first side wall 14 generally apply to the second side wall 16 as well. The first side wall 14 includes opposing upper and lower ends 26, 28, opposing front and rear sides 30, 32, and opposing interior and exterior faces or sides 34, 36. The interior side 34 faces the second side wall 16 when the first and second side walls 14, 16 are in the deployed position. In this position, the lower end 28 of the first side wall 14 abuts and is supported by the base 12.
The first side wall 14 is releasably coupled to the base 12. The first side wall 14 is movable between two or more discrete positions (positioned along the longitudinal axis LA) to be selectively supported at one of the two or more discrete positions in order to change the distance between the first and second side walls 14, 16 to conform the distance to the planar objects O (e.g., a dimension thereof). For example, the first side wall 14 may be moved relative to (e.g., on or along) the base 12 between the extended position, the contracted position, and one or more intermediate positions. The first side wall 14 includes at least one post 48 configured to engage the base 12 when the first side wall 14 is at one of the discrete longitudinal positions. For example, a first post 48 may be adjacent the front side 30, and/or a second post 48 may be adjacent the rear side 32. Each post 48 extends downward from the lower end 28 of the first side wall 14. In the illustrated example, each post 48 includes ribs 49 extending along respective front and rear sides of the post.
The base 12 defines the two or more discrete positions. The base 12 includes a plurality of receivers 50 (shown in FIG. 7 ) for use in coupling to the first side wall 14 (and, accordingly, for coupling to the second side wall 16 as well). For example, each receiver 50 may be configured to receive one of the posts 48. The receivers 50 may be spaced longitudinally along the base 12 at the discrete increments such that each receiver 50 defines one discrete longitudinal position. For example, one of the receivers 50 (e.g., an extended position receiver) may define the discrete position associated with the extended position, one of the receivers 50 (e.g., a contracted position receiver) may define the discrete position associated with the contracted position, and one of the receivers 50 (e.g., an intermediate position receiver) may define one of the one or more intermediate positions. In the illustrated embodiment, the outermost receiver 50 (e.g., the receiver 50 closest to the first end 22 of the base 12) is the extended position receiver, the inner most receiver 50 (e.g., the receiver 50 closest to the middle of the base 12) is the contracted position receiver, and the receivers 50 disposed between the contracted and extended position receivers 50 are the intermediate position receivers 50. In some examples, the receivers 50 are spaced apart by discrete increments of about 2.0 inches (5.1 centimeters), although other distances are within the scope of the present disclosure. Each receiver 50 may include (e.g., define) a post recess sized and shaped to receive the post 48 (including ribs 49 in some examples) to position the first side wall 14 at the discrete longitudinal position defined by the receiver 50 (when the first side wall 14 is in the deployed position). The post recess of each receiver 50 extends generally downward from the upper surface 18 of the base 12. In some examples, the base 12 includes at least one set of receivers 50 for each post 48 of the first side wall 14. For example, in the illustrated embodiment, the base 12 includes a first set of receivers 50 corresponding to the first post 48 adjacent the front side of the base 12 and a second set of receivers 50 corresponding to the second post 48 adjacent the rear side of the base 12. Each set of receivers 50 may include a respective plurality of receivers 50 including an extended position receiver 50, a contracted position receiver 50, and/or one or more intermediate position receivers 50. As illustrated, the base 12 includes receivers 50 for the second side wall 16 that are generally identical (e.g., mirror image thereof) to the receivers 50 for the first side wall 14. Thus, the descriptions regarding the receivers 50 for the first side wall 14 also apply to the receivers 50 for the second side wall 16.
The first side wall 14 is selectively coupled to at least one of the receivers 50 when the first side wall 14 is coupled to the base 12 in the deployed position. For example, the first side wall 14 is coupled to the extended position receiver 50 when the first side wall 14 is coupled to the base 12 in the extended position and to the contracted position receiver 50 when the first side wall is coupled to the base 12 in the contracted position. Specifically, the first post 48 of the first side wall 14 is selectively disposed in the extended position receiver 50 of one set when the first side wall 14 is coupled to the base 12 in the extended position and in the contracted position receiver 50 of the same set when the first side wall 14 is coupled to the base 12 in the contracted position. Likewise, the second post 48 of the first side wall 14 is selectively disposed in the extended position receiver 50 of the other set when the first side wall 14 is coupled to the base 12 in the extended position and in the contracted position receiver 50 of said other set when the first side wall 14 is coupled to the base 12 in the contracted position. In a similar manner, the first side wall 14 is coupled to one of the intermediate receivers 50 when the first side wall 14 is coupled to the base 12 at one of the intermediate positions. Specifically, the first post 48 of the first side wall 14 is selectively disposed in one of the intermediate position receivers 50 of one set when the first side wall 14 is coupled to the base 12 in one of the intermediate positions. Likewise, the second post 48 of the first side wall 14 is selectively disposed in one of the intermediate position receivers 50 of the other set when the first side wall 14 is coupled to the base 12 in the one of the intermediate positions.
Referring to FIGS. 10-16 , the transport container 10 includes at least one brace 52 configured to secure the first side wall 14 in the deployed position. In the illustrated embodiment, the transport container 10 includes two braces 52 for securing the first side wall 14 in the deployed position. The two braces 52 are similar or generally identical (e.g., the braces 52 are mirror images of each other). Accordingly, the one brace 52 will be described in further detail herein with the understanding that the other brace 52 has essentially a similar or the same construction. Thus, descriptions regarding one brace 52 generally apply to the other brace 52 as well. The brace 52 is elongate and includes opposing first and second end portions 54, 56 (e.g., wall and base end portions, respectively). The wall end portion 54 is coupled to the first side wall 14. In particular, the wall end portion 54 of the brace 52 is movably (e.g., rotatably) coupled the first side wall 14. The wall end portion 54 of the brace 52 defines a shaft opening through which a shaft 58 (shown in FIG. 14 ) of the first side wall 14 extends to rotatably couple the brace 52 to the first side wall 14. This movement allows the brace 52 to move between a bracing position (shown in FIGS. 1 and 2 ) and a stowed position (shown in FIG. 17 ). In addition, because the brace 52 is coupled to the first side wall 14, the brace 52 moves with the first side wall 14 (e.g., substantially along the longitudinal axis LA) as the first side wall 14 moves between the different positions (e.g., between the extended position and the contracted position).
In the bracing position, the brace 52 secures the first side wall 14 in the deployed position. In other words, the first side wall 14 is restricted from moving between the collapsed position and the deployed position. Specifically, the brace 52 engages the base 212 in the bracing position to secure the first side wall 14 in the deployed position. The base end portion 56 is configured to be releasably attached to the base 12. The base end portion 56 includes at least one brace interconnection member 60 configured to mate and connect with at least one base interconnection member 62 (shown in FIG. 52 ) of the base 12, or at least a portion thereof. The engagement and mating between the brace interconnection member 60 and the base interconnection member 62 restricts or inhibits movement of the brace 52, and by extension the first side wall 14, relative to the base 12. Specifically, the interconnection of the brace and base interconnection members 60, 62 inhibits longitudinal movement and rotational movement about an axis (not shown) generally perpendicular to the longitudinal axis LA and generally parallel to the upper surface 18 of the brace 52 and the first side wall 14. As a result, the brace 52 generally braces, strengthens and stiffens the first side wall 14 when the first side wall 14 is in the deployed position.
In the illustrated embodiment, the brace interconnection member 60 includes a plurality of plurality of projections or fingers 64. The fingers 64 are spaced apart from each other. The base interconnection member 62 is disposed on and extends longitudinally along a side (e.g., a front side, a rear side) of the base 12. It is understood the base 12 includes at least one base interconnection member 62 on the front side and the rear side of the base 12 for engaging two braces 52, respectively, bracing the first side wall 14. The base interconnection member 62 defines a plurality of recesses 66. Each recess 66 is sized and shaped to correspond to and receive one of the fingers 64 of the brace 52, thereby restricting or inhibiting movement between the brace 52 (and the first side wall 14) and the base 12. The recesses 66 of the base interconnection member 62 are arranged longitudinally, in a linear manner along the side of the base 12. The recesses 66 are arranged to correspond to the discrete positions the base 12 defined for the first side wall 14 so that regardless of what longitudinal position the first side wall 14 is in (e.g., extended position, contracted position, etc.), at least a portion of the recesses 66 are arranged to receive the fingers 64 of the brace 52. Accordingly, regardless of what discrete longitudinal position the first side wall 14 is in, the brace interconnection member 60 of the brace 52 may be interconnected with at least a portion of the base interconnection member 62 of the base 12 to secure the first side wall 14 in the deployed position.
In the bracing position, the brace 52 extends from a side (e.g., front side 30) of the first side wall 14 to a side (e.g., a front side) of the base 12. As illustrated in FIGS. 1 and 2 , the brace 52 extends over the open front or rear side of the transport container 10. Thus, the brace 52 may act as an object support and is configured to restrict or inhibit the one or more objects O from moving in at least one of a rearward direction or a forward direction. In other words, the brace 52 is configured to brace the one or more objects O to keep the objects O on the transport container 10. The rearward and forward directions are generally opposite of one another and generally perpendicular to the longitudinal axis LA. The brace 52 may provide lateral support (e.g., generally perpendicular to the longitudinal axis LA) to the one or more objects O on the transport container 10. For example, by extending over the open front side of the transport container 10, the brace 52 may generally inhibit the one or more objects O from moving in the forward direction.
In the stowed position (as shown in FIG. 17 ), the brace 52 does not secure the first side wall 14 in the deployed position. Accordingly, when the brace 52 is in the stowed position, the first side wall 14 is free to move between the collapsed position and the deployed position. In the stowed position, the brace 52 may not engage the base 12 and be in a stored arrangement. In the illustrated embodiment, the first side wall 14 defines a brace recess 68 (shown in FIG. 6 ). The brace recess 68 is sized and shaped to receive the brace 52 when the brace 52 is in the stowed position. In other words, in the stowed position, the brace 52 is disposed in the brace recess 68. The brace recess 68 is disposed on the exterior side 36 of the first side wall 14. The first side wall 14 may be configured to hold the brace 52 in the stowed position. For example, the first side wall 14 may form an interference fit with the brace 52 (at least a portion thereof) to hold the first side wall 14 in the stowed position.
The brace 52 rotates between the stowed position and the bracing position about the shaft 58 of the first side wall 14. Referring to FIGS. 11-13, 15 and 16 , the brace 52 includes a retainer 70 (e.g., a brace retainer) configured to secure the brace 52 in the bracing position. For example, the brace retainer 70 may restrict or inhibit the brace 52 from moving or rotating about the shaft 58 between the stowed position and the bracing position (e.g., inhibits the unintentional disconnection of the brace and base interconnection members 60, 62).
The brace retainer 70 is configured to engage the base 12 to secure the brace 52 in the bracing position. In the illustrated embodiment, the brace retainer 70 is generally a latch. The brace retainer 70 includes a body 72. The body 72 is mounted on and slidable relative to the brace 52. A handle 73 extends outward from the body 72. The body 72 is movable (e.g., slidable) between a coupling position (shown in FIGS. 12 and 13 ) and a release position (not shown). Using the handle 73, a user may manually move the body 72, such as from the coupling position to the release position. The body 72 is configured to engage the base 12 in the coupling position (when the brace 52 is in the bracing position). The body 72 includes a detent 74 that engages the base 12 when the brace retainer 70 is in the coupling position and the brace 52 is in the bracing position. In the illustrated embodiment, each rail 29, 31 of the base 12 defines a channel 78 therein. The channel 78 is defined along each side of the base 12. The channel 78 faces upwardly and is generally parallel to the longitudinal axis LA. When the brace retainer 70 is in a coupling position (shown in FIGS. 12 and 13 ), the detent 74 of the body 72 is disposed in or extended into one of the channels 78, thereby securing the brace 52 in the bracing position. The engagement of the detent 74 with the portion of the rail 29, 31 defining the channel 78 restrict or inhibits rotation of the brace 52 about the shaft 58. Since the channel 78 is elongate and extends parallel to the longitudinal axis LA, the detent 74 may be inserted into the channel 78 to secure the brace 52 in the bracing position, regardless of the longitudinal position of the brace 52 and/or first side wall 14.
The brace retainer 70 is resiliently biased toward the coupling position. The brace retainer 70 includes a spring 75. The spring 75 resiliently biases the body 72 (e.g., detent 74) of the brace retainer 70 toward the coupling position. One end of the spring 75 engages the brace 52 and the opposite end of the spring 75 engages the body 72. In the illustrated embodiment, the brace retainer 70 is an integrally formed, one-piece component. Accordingly, the body 72 and the spring 75 are integrally-formed with each other. Other configurations are within the scope of the present disclosure. For example, the body 72 and the spring 75 can be separate components. To move the brace 52 from the bracing position to the stowed position, the brace retainer 70 is moved to the release position. To move the brace retainer 70 toward the release position, the user uses the handle 73 to move or slide the brace retainer 70 away from the base 12 (e.g., substantially upward) to move the detent 74 out of the channel 78. The brace retainer 70 is configured to automatically move toward or to the release position when the brace 52 is moved from the stowed position to the bracing position. The detent 74 includes an angled surface or ramp 76. As the brace 52 is moved toward the bracing position, the ramp 76 engages and slides along the base 12, thereby pushing the brace retainer 70 toward the release position as the brace 52 is moved closer to the bracing position. This moves the brace retainer 70 away from the base 12 until the detent 74 can pass over the base 12 and/or rail 29, 31. Once the detent 74 becomes aligned with the channel 78, the spring 75 pushes the brace retainer 70 into the coupling position, thereby pushing the detent 74 into the channel 78. In the illustrated embodiment, the brace retainer 70 (e.g. body 72) includes a stop 71 that engages the brace 52 or a portion thereof to restrict or limit the movement of the brace retainer 70 away from the coupling position (e.g., to position the brace retainer 70 in the release position).
Referring to FIG. 14 , the brace 52 is configured to slide along the shaft 58 of the first side wall 14 as the brace moves between the bracing position and the stowed position. Generally, the brace 52 moves downward along the shaft 58 to engage the base 12 and vertically align the brace interconnection member 60 with the base interconnection member 62. By sliding the brace 52 along the shaft 58, the brace 52 is able to be disposed within the first side wall 14 when the brace 52 is in the stowed position, providing a more compact configuration. The brace 52 and the first side wall 14 include corresponding helical surfaces or ramps 80 and 82, respectively. The helical ramps 80, 82 extend at least partially around the shaft 58. The helical ramps 80, 82 of the respective brace 52 and the first side wall 14 may engage each other as the brace 52 is rotated between the stowed position and the bracing position to facilitate rotation of the brace 52 about the shaft 58 and/or to facilitate the sliding of the brace 52 along the shaft 58 to vertically position the brace 52 to engage the base 12 and vertically align the brace interconnection member 60 with the base interconnection member 62. In the illustrated embodiment, the helical ramp 80 of the brace 52 is disposed toward the upper end of the opening in the brace 52 through which the shaft 58 extends, with the helical ramp 82 of the first side wall 14 arranged accordingly. In another embodiment, in addition to or instead of the helical ramp 80 of the brace 52, the brace 52 may include a helical ramp (similar to helical ramp 80) toward the lower end of the opening in the brace 52 through which the shaft 58 extends, with the first side wall 14 including a helical ramp (similar to helical ramp 82) arranged accordingly. Other configurations are within the scope of the present disclosure. For example, in some examples, the transport container 210 may not include helical ramps 80, 82.
Having described the features and elements of one brace 52, it is appreciated that the other braces 52 of the transport container 10 includes these same features and elements, as indicated in the drawings.
Referring to FIG. 5 , the transport container 10 (e.g., the first side wall 14) may include one or more adjustable object supports 84. The adjustable object support 84 provides lateral support to the one or more objects O on the transport container 10. The adjustable object supports 84 are movable between a stowed position (shown in FIG. 5 ) and a support position (not shown). Further details of the adjustable object supports 84 and associated elements, including the associated elements of the first side wall 14, can be found in U.S. application Ser. No. 17/175,741, filed on Feb. 15, 2021.
Referring to FIGS. 5 and 6 , the first side wall 14 includes at least one first stacking projection 91. The first stacking projection 91 is configured to engage the base 12 of a second transport container 10 (not shown) stacked on the first side wall 14 to restrict or inhibit longitudinal movement of the second transport container 10 relative to the first transport container 10. The first stacking projection 91 extends generally upward from the upper end 26 of the first side wall 14. Referring to FIG. 4 , the base 12 includes (e.g., defines) a plurality or set of stacking recesses 93. Each stacking recess 93 extends generally upward from the lower surface 20 of the base 12. Each stacking recess 93 is sized and shaped to receive a first stacking projection 91 of another (e.g., second) transport container 10, when the second transport container 10 is stacked on the first transport container 10. The first stacking projection 91 and the stacking recess 93 may have generally any shape, as long as the shapes correspond to one another. The mating engagement between one of the stacking recesses 93 of a second transport container 10 and the first stacking projection 91 of the first transport container 10 facilitates the securement and aligning of the second transport container 10 on the first transport container 10 when the second transport container 10 is stacked on the first transport container 10. Specifically, the mating engagement between one of the stacking recesses 93 of a second transport container 10 and the first stacking projection 91 of the first transport container 10 restricts or inhibits longitudinal movement of the two stacked transport containers 10 relative to one another. Each set of stacking recesses 93 may be arranged longitudinally in a linear manner along the base 12. In some examples, the stacking recesses 93 are arranged to correspond to the discrete positions the base 12 defines for the first side wall 14 so that regardless of what longitudinal position (e.g., extended position, contracted position, etc.) the first side wall 14 of the lower transport container 10 is in, one of the stacking recesses 93 of the upper transport container 10 is positioned to receive the first stacking projection 91 of the first side wall 14. Accordingly, regardless of what discrete longitudinal position the first side wall 14 is in, the first side wall 14 of a first or lower transport container 10 can be used to support and secure the base 12 of a second or upper transport container 10 stacked thereon.
Referring to FIGS. 5-7 and 9 , the first side wall 14 includes first and second locators 38 (broadly, at least one locator). The locators 38 are configured to engage the base 12 to facilitate the positioning of the first side wall 14 in the deployed position and the collapsed position. The first locator 38 extends generally forward from the front side 30 of the first side wall 14 and the second locator 38 extend generally rearward from the rear side 32 of the first side wall 14. When the first side wall 14 is in the deployed position, the first locator 38 engages or rests on the first rail 29 of the base 12 and the second locator 38 engages or rests on second rail 31 of the base 12. The first and second rails 29, 31 of the base 12 each define locator recesses 40 (shown in FIGS. 7 and 9 ). Each locator recess 40 is sized and shaped to receive one of the locators 38. Each locator recess 40 extends generally downward from an upper surface of its respective first or second rail 29, 31. When the first side wall 14 is in the collapsed position, the first locator 38 is disposed in the locator recess 40 of the first rail 29 (shown in FIG. 18 ) and the second locator 38 is disposed in the locator recess 40 of the second rail 31. Positioning each locator 38 in its corresponding locator recess 40, positions and orients the first side wall 14 on the base 12 when the first side wall 14 is in the collapsed position. The reception of the locators 38 by the locator recesses 40 restricts or inhibits longitudinal movement of the first side wall 14 relative to the base 12 when the first side wall 14 is in the collapsed position to help keep the first side wall 14 on the base 12.
Having described the features and elements of the first side wall 14, it is appreciated that the second side wall 16 includes these same features and elements, as indicated in the drawings.
Referring to FIGS. 17-20 and as mentioned above, the first and second side walls 14, 16 are movable between a deployed position (shown in FIGS. 1 and 2 ) and a collapsed position (shown in FIG. 17 ). In this manner, the transport container 10 may be moved between a deployed configuration and a collapsed configuration. In the deployed position, the first and second side walls 14, 16 are arranged to receive the one or more objects O therebetween. The first and second side walls 14, 16 are erected or generally upright when in the deployed position. For example, in the illustrated embodiment, the first and second side walls 14, 16 extend substantially perpendicular to the base 12 in the deployed position. The first and second side walls 14, 16 can be in any one of the extended position, the contracted position, or the one or more intermediate positions when in the deployed position. In the collapsed position, the first and second side walls 14, 16 are arranged to reduce the overall size and shape of the transport container 10. The first and second side walls 14, 16 lay generally flat on the base 12 when in the collapsed position. For example, in the illustrated embodiment, the first and second side walls 14, 16 extend substantially parallel to the base 12 in the collapsed position. The first and second side walls 14, 16 are independently movable between the deployed position and the collapsed position. The first and second side walls 14, 16 are moved substantially along a second or vertical axis (not shown) between the deployed position and the collapsed position. The second axis is substantially perpendicular to the upper surface 18 of the base 12 and is substantially perpendicular to the longitudinal axis LA.
The transport container 10 has a first height H1 (shown in FIG. 1 ) when the first and second side walls 14, 16 are in the deployed position. Specifically, the first and second side walls 14, 16 have a first height (e.g., first wall height) WH1 (shown in FIG. 2 ) when in the deployed position. The transport container 10 has a second height H2 (shown in FIG. 17 ) when the first and second side walls 14, 16 are in the collapsed position. Specifically, the first and second side walls 14, 16 have a second height (e.g., second wall height) WH2 (shown in FIG. 17 ) when in the collapsed position. The second height H2 of the transport container 10 is different than the first height H1 of the transport container 10, and the second wall height WH2 is different than the first wall height WH1. In particular, the second height H2 of the transport container 10 is less than the first height H1, and the second wall height WH2 is less than the first wall height WH1. Placing the first and second side walls 14, 16 in the collapsed position makes it easier to transport the transport container 10 when the transport container 10 is empty (e.g., when no objects O are on the base 12) and to pack several transport containers 10 together and return them after the transport containers 10 have been used to deliver the one or more objects O.
In the collapsed position, the first and second side walls 14, 16 extend in a substantially horizontal direction. In this position, the first and second side walls 14, 16 lay generally flat on and/or overlies the base 12. The interior side 34 of each side wall 14, 16 faces and/or engages the upper surface 18 of the base 12. In the collapsed position, a portion of each of the first and second side walls 14, 16 is disposed between the first and second rails 29, 31, with the front and rear sides 30, 32 of each side wall 14, 16 overlying and/or engaging the respective first and second rails 29, 31. Positioning a portion of the first and second side walls 14, 16 between the first and second rails 29, 31 facilitates the positioning and orienting of the side walls 14, 16 on the base 12 in the collapsed position and restricts or inhibits lateral movement of the first and second side walls 14, 16 relative to the base 12. In the illustrated embodiment, the lower end of the posts 48 of the first and second side walls 14, 16 are substantially aligned with the respective ends 22, 24 of the base 12 when in the collapsed position. The arrangement of the first and second side walls 14, 16 in the collapsed position forms a relatively wide platform to support another transport container 10, such as one in the collapsed configuration, stacked thereon (not shown).
The first and second side walls 14, 16 each include first and second retainers 70 (e.g., side wall retainers). The first and second retainers 70 are generally identical to the retainers 70, described above, that are part of the braces 52 and, thus, the descriptions herein regarding the retainers 70 of the braces 52 apply to these first and second retainers 70, unless clearly stated or indicated otherwise. At least one retainer 70 of each side wall 14, 16 is configured to engage the base 12 to secure the respective side wall 14, 16 in the collapsed position. For example, the first retainer 70 of each side wall 14, 16 may be arranged to engage the first rail 29, and/or the second retainer 70 of each side wall 14, 16 may be arranged to engage the second rail 31. In the coupling position, the detents 74 of the first and second retainers 70 are disposed in or received by detent recesses 42 (shown in FIG. 20 ) defined by the first and second rails 29, 31. The engagement of the detent 74 with the portion of the rail 29, 31 defining the detent recess 42 secures the respective side wall 14, 16 to the base 12 in the collapsed position. As described above, the first and second retainers 70 are biased in the coupling position by the springs 75. The first and second retainers 70 of each side wall 14, 16 are manually moved to the release position, as described above, in order to move the first and second side walls 14, 16 from the collapsed position.
Referring to FIG. 21 , the transport container 10 may include first and second ramps 43. The first and second ramps 43 are releasably coupleable to the base 12. Each ramp 43 includes a post 46, similar to the posts 48 of the first and second side walls 14, 16 that can be inserted into one of the receivers 50 to couple the ramp 43 to the base. The ramps 43 make it easier to load the planar objects O onto the base 12. When coupled to the base 12, the ramps 43 provide a path for a cart or dolly carrying one or more planar objects O to be rolled up onto the base 12 to deposit the planar objects O on the base 12.
As is now apparent, the transport container 10 is movable between a collapsed configuration (shown in FIG. 17 ) and a deployed configuration (shown in FIGS. 1 and 2 ). In the collapsed configuration, the first and second side walls 14, 16 are in their collapsed positions and the braces 52 are in their stowed positions. In the collapsed configuration, several transport containers 10 may be stacked on top of each other in a relatively compact manner so that the transport containers 10 may be transported or returned to the sender of the one or more objects 0. In the deployed configuration, the first and second side walls 14, 16 are in their deployed positions (e.g., extended position, contracted position, intermediate position) and the braces 52 are in their bracing position. The first and second side walls 14, 16 may be at generally any longitudinal location relative to the base 12 to conform the transport container 10 to the size of the one or more objects being carried. For example, the first and second side walls 14, 16 may be in the contracted position, which generally corresponds to the second distance D2 (shown in FIG. 2 ), or the first and second side walls 14, 16 may be in the extended position, which generally corresponds to the first distance D1 (shown in FIG. 1 ). For example, the first and second side walls 14, 16 may be positioned to receive objects O, such as solar panels, having a length of about 65 inches (about 1.65 meters) (e.g., in the contracted position) or about 77 inches (about 1.96 meters) (e.g., in the extended position), although other arrangements are within the scope of the present disclosure. When supported by the transport container 10, the length (broadly, a dimension) of the one or more objects O is generally parallel to the longitudinal axis LA of the transport container 10.
In operation, to collapse the transport container 10 from the deployed configuration, the operator moves the braces 52 to the stowed position. To move each brace 52, the user moves the brace retainer 70 to the release position and then the brace 52 is moved (e.g., rotated) to the stowed position. After, the first and second side walls 14, 16 are moved upward or lifted up relative to the base 12 until the posts 48 are free of the receivers 50 and then the side walls 14, 16 are laid down on the base 12 in the collapsed position (shown in FIG. 17 ). As the first and second side walls 14, 16 are moved toward, the ramp 76 of the first and second retainers 70 engage and slide along the base 12 on respective rails 29, 31, thereby pushing the retainers 70 toward the release position as the side walls 14, 16 are moved closer to the collapsed position. Once the detents 74 of the first and second retainers 70 become aligned with their respective detent recess 42, the spring 75 pushes the retainers 70 into the coupling position, thereby pushing the detents 74 into the respective detent recesses 42, securing the side walls 14, 16 to the base 12.
To erect the transport container 10 to the deployed configuration from the collapsed configuration, the operator first releases the first and second side walls 14, 16 from the base 12 by moving the first and second retainers 70 of each side wall 14, 16 to the release position. After the first and second side walls 14, 16 are released, the user moves or lifts the side walls 14, 16 to align the posts 48 with the desired receivers 50 (e.g., at the desired longitudinal position such as the extended position, contracted position, etc.) and then moves or lowers the respective first or second side walls 14, 16 toward the base 12 to insert the posts 48 into the desired receivers 50. Erection of the first and second side walls 14, 16 is completed when the lower end 28 of each side wall 14, 16 abuts the base 12 and the locators 38 of each side wall 14, 16 abut the base 12. After the first and second side walls 14, 16 are in the upright position, the braces 52 are moved to bracing position. The brace retainer 70 of each brace 52 is moved, via the spring 75 or manually, to the coupling position once the brace 52 is in the bracing position to secure the brace 52 in the bracing position. After the transport container 10 is erected, one or more of the adjustable object supports 84 may be moved (before or after the objects O are loaded into the transport container 10) for bracing the one or more objects O supported by the transport container 10.
The first and second side walls 14, 16 can be moved between different positions to conform the distance between the first and second side walls 14, 16 to a dimension of the planar objects O. Once erected, to change the distance between the first and second side walls 14, 16, first the brace retainers 70 are moved to the release position and the associated braces 52 disengaged from the base 12. Afterwards, one or both of the first and second side walls 14, 16 are removed from their existing position (e.g., a first position) on the base 12. The first and/or second side walls 14, 16 are lifted upward, disconnecting or withdrawing the posts 48 from the receivers 50. The first and/or second side walls 14, 16 are then reattached to the base at a new position (e.g., a second position) on the base 12. This new position is different than the first position and is selected by the user so that the distance between the first and second side walls 14, 16 conforms to the dimension of the planar objects O. To reattach the first and/or second side walls 14, 16, one or each side wall 14, 16 (e.g., the posts 48 thereof) are aligned with the desired receivers 50 (e.g., at the desired second position) and then moved toward the base 12 to insert the posts 48 into the desired receivers 50. The braces 52 are then reattached to the base 12 as described above.
It is apparent and understood that the elements, features, and/or teachings set forth in each embodiment disclosed herein are not limited to the specific embodiment(s) the elements, features, and/or teachings are described in. Accordingly, it is apparent and understood that the elements, features, and/or teachings described in one embodiment may be applied to one or more of the other embodiments disclosed herein. For example, it is understood that any of the transport containers disclosed herein can include the adjustable object supports 284 shown in FIGS. 58-60 .
Various objects and advantages of the present disclosure is thus apparent from the description herein taken in conjunction with the accompanying drawings wherein, by way of illustration and example, certain embodiments of this disclosure are set forth. The drawings submitted herewith constitute a part of this specification, include exemplary embodiments of the present disclosure, and illustrate various objects and features thereof.
Modifications and variations of the disclosed examples are possible without departing from the scope of the disclosure defined in the appended claims. For example, where specific dimensions are given, it will be understood that they are exemplary only and other dimensions are possible.
When introducing elements of the present disclosure or the example(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions, products, and methods without departing from the scope of the present disclosure, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

What is claimed is:

1. A transport container for carrying one or more generally planar objects, the transport container comprising:

a base configured to support the one or more generally planar objects; and

first and second side walls removably coupled to opposing ends of the base, the first and second side walls movable substantially along a first axis between an extended position and a contracted position, the first side wall spaced from the second side wall a first distance when the first and second side walls are in the extended position and a second distance when the first and second side walls are in the contracted position, the second distance different from the first distance;

wherein the first and second side walls are movable substantially along a second axis between a deployed position and a collapsed position, the first and second side walls having a first height in the deployed position and a second height different than the first height in the collapsed position.

2. The transport container of claim 1, wherein the first and second side walls are each removably couplable to the base in one of the extended position or the contracted position.

3. The transport container of claim 1, wherein the first and second side walls move in opposite directions when moving between the extended position and the contracted position.

4. The transport container of claim 1, wherein the base includes a first extended position receiver and a first contracted position receiver, the first side wall selectively coupled to the first extended position receiver when the first side wall is coupled to the base in the extended position and to the first contracted position receiver when the first side wall is coupled to the base in the contracted position.

5. The transport container of claim 4, wherein the first side wall includes a post selectively disposed in the first extended position receiver when the first side wall is coupled to the base in the extended position and in the first contracted position receiver when the first side wall is coupled to the base in the contracted position.

6. The transport container of claim 4, wherein the base includes a second extended position receiver and a second contracted position receiver, the second side wall selectively coupled to the second extended position receiver when the second side wall is coupled to the base in the extended position and to the second contracted position receiver when the second side wall is coupled to the base in the contracted position.

7. The transport container of claim 6, wherein the second side wall includes a post selectively disposed in the second extended position receiver when the second side wall is coupled to the base in the extended position and in the second contracted position receiver when the second side wall is coupled to the base in the contracted position.

8. The transport container of claim 4, wherein the base includes one or more intermediate receivers between the first extended position receiver and the first contracted position receiver, the first side wall selectively coupled to one of the one or more intermediate receivers when the first side wall is coupled to the base in an intermediate position between the extended and contracted positions.

9. The transport container of claim 1, wherein the first and second side walls extend substantially perpendicular to the base in the deployed position.

10. The transport container of claim 1, wherein the first and second side walls extend substantially parallel to the base in the collapsed position.

11. The transport container of claim 1, further comprising first and second braces movable between a bracing position and a stowed position, the first and second braces engaging the base in the bracing position.

12. The transport container of claim 1, further comprising first and second braces each including a retainer configured to engage the base to secure the respective first and second brace in a bracing position.

13. The transport container of claim 12, wherein each retainer is resiliently biased toward a coupling position, each retainer engaging the base when the respective retainer is in the coupling position and the respective first and second brace is in the bracing position.

14. The transport container of claim 12, wherein each retainer includes a body configured to engage the base in a coupling position and a spring resiliently biasing the body toward the coupling position, the body and the spring integrally formed with each other.

15. The transport container of claim 11, wherein the first and second braces move substantially along the first axis with the first and second side walls as the first and second side walls are moved between the extended position and the contracted position.

16. The transport container of claim 1, further comprising a first brace configured to secure the first side wall in the deployed position and a second brace configured to secure the second side wall in the deployed position.

17. The transport container of claim 1, further comprising first and second braces movable between a bracing position and a stowed position, wherein, when the first and second braces are in the bracing position, the first and second side walls are restricted from moving between the collapsed position and the deployed position, and when the first and second braces are in the stowed position, the first and second side walls are free to move between the collapsed position and the deployed position.

18. The transport container of claim 1, further comprising at least one ramp coupleable to the base.

19. A transport container for carrying one or more generally planar objects, the transport container comprising:

a base configured to support the one or more generally planar objects, the base defining two or more discrete positions along a first axis;

a first side wall supported by the base;

a second side wall moveable between the two or more discrete positions to be selectively supported at one of the two or more discrete positions in order to change a distance between the first and second side walls to conform the distance to a dimension of the one or more generally planar objects;

wherein the first and second side walls are movable substantially along a second axis between a deployed position and a collapsed position, wherein in the deployed position the first and second side walls are substantially upright and in the collapsed position the first and second side walls lay substantially flat on the base.

20. A method of conforming a transport container that carries one or more generally planar objects to a dimension of the one or more generally planar objects, the method comprising:

moving first and second side walls from a collapsed position in which the first and second side walls lie substantially flat on a base to a deployed position in which the first and second side walls are substantially upright and are supported by the base;

removing one or both of the first and second side walls from a first position on the base and;

reattaching said one or both of the first and second side walls at a second position on the base different than the first position such that a distance between the first and second side walls conforms to the dimension of the one or more generally planar objects.