WO2006136547A1

WO2006136547A1 - Method of forming a unit load

Info

Publication number: WO2006136547A1
Application number: PCT/EP2006/063336
Authority: WO
Inventors: Edward Fuller; Moise Vlad; Whiteside Willis; Jonathan North
Original assignee: Inter Ikea Systems B.V.
Priority date: 2005-06-21
Filing date: 2006-06-20
Publication date: 2006-12-28

Abstract

The present invention concerns a method of forming a unit load (1), comprising a number of boxes (5) in several layers and at least two loading ledges (2, 11, 12, 32) at two opposite lower sides of the unit load (1). The lower-most layer of boxes (5) placed on the loading ledges (2, 11, 12, 32) is formed into a separate, stabilizing base unit (4). The other layers of boxes (5) are placed on the base unit (4) after the forming of the base unit. The present invention also concerns the stabilizing base unit (4) and a fixture to be used in the forming of the unit load (1).

Description

INTER IKEA SYSTEMS B. V. METHOD OF FORMING A UNIT LOAD

Technical Field

The present invention concerns a method of forming a unit load comprising a number of boxes placed on two or more loading ledges. The boxes are placed in several layers upon each other and with several boxes in each layer. The lowermost layer is formed into a base unit, which base unit normally also includes a lower stabilizing or support part. In some instances it is beneficial to use a fixture when forming the unit load.

Prior Art

Today it is common to use wooden pallets for transportation and storing of boxes of different s^'izes. The wooden pallets are often of a standardized size. In some instances the wooden pallets are replaced by loading ledges, of the type e.g. shown in WO 02/038471 or WO 04/026713. Both loading ledges and pallets have their pros and cons. Loading ledges are adapted to the actual size of the load. Thus, they are flexible in that they adapt them- selves to the load and not the other way around as for pallets, to which the load has to be adapted. However, loading ledges have no inherent stability, i.e. they have to cooperate with the load in forming a stable unit. This also means that they need to be supported in the build-up of a load. The pallets have an inherent rigidity and are non- deflecting. However, wooden pallets are to be abandoned in many instances, e.g. due to governmental restriction regarding use of wood in cross border transportations. Thus, there is a need for a replacement of the wooden pallets that are rigid enough and non-deflecting. Summary of the Invention

The present invention concerns a method of forming a unit load, in which a base unit is formed of loading ledges, a support part, a layer of boxes and possible fur- ther parts. Said layer of boxes being the lowermost layer of boxes in the unit load. By means of the base unit a rigid and non-deflecting part is formed on which further layers of boxes may be placed. In order to facilitate the forming of the base unit and a subsequent unit load a fix- ture for the loading ledges may be used. The fixture may also be used in forming unit loads even if no specific base unit is formed. The loading ledges are placed in the fixture in a supported way.

The base unit on which the rest of the unit load is formed gives a rigid and non-deflecting part, comparable with a standard pallet that is rigid and non-deflecting. The degree of rigidity is directly related to the weight and deflection characteristics of the individual units making up the unit load. For highly compressible and extremely flexible load, such as bananas, the challenge is at the extreme end of the continuum. The support part of the base unit normally includes a rigid mat or beams placed between the loading ledges below the first layer of boxes, contributing to the rigidity of the base unit and controlling de- flection at the centre of the load. The first layer of boxes forming the base unit may be furnished with corner boards placed at the upper and possibly lower edges of the layer and is strapped with the loading ledges and support parts. By means of the straps and the corner boards the risk of outward sag and inward deflection is reduced.

Further objects and advantages of the present invention are obvious for a person skilled in the art when reading the detailed description below of at present preferred embodiments . Brief Description of the Drawings

The present invention will be explained further below in a detailed description by way of examples and with reference to the enclosed drawings. In the drawings: Fig. 1 shows one example of a unit load according to the present invention;

Figs. 2 and 3 show two different examples of loading ledges possible to use when forming the unit loads;

Fig. 4 shows one example of a base unit according to the present invention in exploded view;

Fig. 5 shows the formed base unit of Fig. 4;

Fig. 6 shows one example of a fixture to be used when forming a unit load;

Fig. 7 shows the parts forming the fixture of Fig. 6 in exploded view, together with loading ledges;

Fig. 8 shows parts of the fixture of Fig. 6 in exploded view;

Fig. 9 shows an alternative support for a base unit according to the present invention; and Fig. 10 shows an example of a fixture for use with the support of Fig. 9.

Detailed Description of Preferred Embodiments As used in this description the expressions "horizon- tal", "vertical", "upper", "lower" and similar expressions refer to the directions in normal use and with reference to the directions of the drawings referred to.

In the embodiments shown in Figs. 1, 4 and 5 a unit load 1 is formed comprising a base unit 4, formed of two or more loading ledges 2, a base mat 3, one layer of boxes 5 and possible upper and lower corner boards -6, 7, 20, further layers of boxes 5 placed on top of the base unit 4 and possible edge protections 8. Furthermore, straps 9 are used to hold the base unit 4 and the unit load 1, respectively, together. In other embodiments adhesives and/or stretch films are used m combination or instead of the straps. To form the unit load 1 and the base unit 4 a fixture 10 may be used.

In Figs. 2 and 3 two examples of loading ledges 11, 12 are shown. In Fig. 4 a further example of loading ledges 2 is indicated, which loading ledges 2 is relatively short and two such loading ledges 2 are placed in line partially overlapping on two opposite sides. The loading ledges 2, 11, 12 to be used in forming the unit load 1 have a general L-shape with a horizontal web 13 and a vertical web 14. A number of feet 15, 16 are placed on the lower side of the horizontal web 13 of each loading ledge 2, 11, 12. Normally one foot 15 is placed at each end of the loading ledge 2, 11, 12 and at least one foot 16 is placed between said feet 15 at the ends. If the at least one foot 16 is only one foot it is normally placed in the middle of the loading ledge 11, 12. The height and placement of the feet 15, 16 are adapted to standard load handling equipment, such as forklifts, hand driven pallet trucks and hydraulic pallet trucks. The loading ledges 2, 11, 12 are normally made of plastics but a person skilled in the art realizes that they may be made of any material giving a stable loading ledge, preferably with low weight. The horizontal web 13 of the loading ledge 12 of Fig. 3 is narrower than the horizontal web 13 of the loading ledge 11 of Fig. 2. The width of the horizontal web 13 of the loading ledge 12 of Fig. 3 corresponds with the width of the feet 5, 6. The embodiments of Figs. 2 and 3 are only two examples of the type of loading ledge that may be used with the present invention. In some instances loading ledges having four or more feet are used. In the shown embodiment (see Figs. 4 and 7) two loading ledges 2 are used on each side, which loading ledges 2 partially overlap in the middle. Said loading ledges 2 have only two feet 15, of which feet one is placed a short dis- tance from one end of the loading ledge 2. In the embodiment of Figs. 4 and 5 the bottom of the base unit 4 is formed by a base mat 3 and four loading ledges 2. The base mat 3 has an outer rectangular form formed by two opposite long sides 17 and two opposite short sides 18. Between the long sides 17 a number of struts 19 are placed parallel with the short sides 18. In other embodiments all four sides have the same length giving a quadratic form to the base mat. The struts 19 are placed in positions where edges of boxes 5 of the base unit 4 are to be placed. Further struts 19 may be furnished to increase the strength of the base mat 3. As indicated in Fig. 4 the struts 19 may have different widths. The base mat 3 has a dimension adapted to the dimension of the boxes 5 forming the layer of the base unit 4. A person skilled in the art realizes that the base mat 3 will have other dimensions and that the struts 19 are placed in other positions if boxes of another dimension will form the base unit. The base mat 3 may be made of wood, cardboard, plastic aluminum or other light metal. At the upper edges of the layer of boxes 5 four corner boards 6 are placed. The corner boards 6 have a general L-form with a horizontal part placed on top of the boxes 5 and a vertical part placed at one side of the boxes 5. Thus, said corner boards 6 are placed surrounding the upper edges of the layer of boxes 5 of the base unit 4. In the shown embodiment further "corner" boards 20 are placed between the boxes 5 of the base unit 3. These further corner boards 20 are placed in right angles to the general extension of the loading ledges 2. In some embodiments lower corner boards 7 are placed between the loading ledges and the layer of boxes 5 of the base unit. The corner boards 6, 7, 20 are made of cardboard or corrugated fiberbόard in this embodiment. A person skilled in the art realizes that the corner boards 6, 7, 20 may be made of any material, such as cardboard, plastic, metal or wood. In Fig. 6 a fixture 10 is shown, intended for use when forming a unit load 1 according to the present invention. The fixture 10 has two short sides 21 and two long sides 22, giving a general rectangular form. A stabilizing brace 23 is placed in the middle between and attached at the ends to the long sides 22. The middle brace 23 is parallel with the short sides 21. On each long side 22 cups 24 are placed to receive feet 15, 16 of loading ledges 2, 11, 12. In the shown embodiment four cups 24 are placed on each long side 22. The four cups 24 of each long side 22 is intended for receiving either relatively long loading ledges having four feet or two relatively short loading ledges 2 placed in line and possibly somewhat overlapping, as indicated in Fig. 7. In the latter case two feet of each load- ing ledge is received in the cups 24 of the long sides 22 of the fixture 10. The cups 24 have a generally rectangular form with inclined sides. The inclination of the cup sides widens upwards .

To facilitate transport, storing etc. the fixture 10 is made of several parts that are relatively easy to put together.

In the shown example each long side 22 of the fixture 10 comprises an elongated bar. The cups 24 are each formed by one cup part 25 with three sides and one cup part 26 forming the fourth side of the cup 24. The cup parts 25, 26 are normally fixed to each other and to the long sides 22 by welding. A person skilled in the art realizes that cup parts 25, 26 may be fixed to each other and/or to the long sides 22 in any other suitable way, e.g. by soldering or with adhesives, rivets or screws. Between the areas of each long side 22 where the cups 24 are to be placed, the long side 22 is beveled 27, in order to facilitate for wheels of a hand driven pallet truck, a pallet jack or the like to cross the long side 22. Each short side 21 and the middle brace of the fix^¬ ture 23 is also formed of an elongated bar. The short sides 21 and possibly the middle brace 23 are beveled 28 in a corresponding way with the bars of the long sides 22 of the fixture 10. In the shown embodiment the short sides 21 and the middle brace 23 are attached to the long sides 22 by means of screws 29, as indicated in Fig. 7. Said screws 29 are received in a plate 30 fixed to the ends of the short sides 21 and the middle brace 23. The plate 30 has openings that are to be aligned with openings in the long sides 22. The openings of the long sides 22 are threaded to cooperate with the screws 29. A person skilled in the art realizes that the fixation may be accomplished in many different ways. The plate 30 is fixed to short sides 21 and the mid- die brace 23 by any suitable fixation, such as by welding, soldering, gluing, rivets or screws.

The fixture 10 is usually given a size corresponding to a standard size used in load handling, e.g. 1200 x 1000 mm. By means of the fixture 10 the first forming of a base unit 4 is simplified in that the loading ledges 2 hold a proper position for forming said base unit 4. The fixture 10 may be made of any suitable material such as plastic, aluminum or other metals. A person skilled in the art realizes that the different parts of the fixture may be made of different materials.

To form the base unit 4 according to the embodiment shown in Figs. 4 and 5 two loading ledges 2 are placed on two opposing sides of the fixture 10. The base mat 3 is placed on top of the horizontal webs 13 of the loading ledges 2. Then a layer of boxes 5 is placed on the base mat 3. Normally corner boards 6 are placed on the upper and outer edges of the layer of boxes 5. Further corner boards 20 are placed between each row of boxes 5. Often edge protections 8 are placed vertically at each corner of the unit load 1. Finally a number of straps 9 are wrapped around the boxes 5, the base mat 3, the corner boards 6, 20, the edge protections 8 and/or the loading ledges 2. In the shown embodiment seven straps 9 are used to hold the base unit 4 together. Two of the straps 9 have a generally horizontal orientation, while the other five straps 9 have a generally vertical orientation. One of the vertical straps 9 is parallel with the general extension of the loading ledges 2. The other four vertical straps 9 are oriented in right angles to the loading ledges 2. The straps 9 are normally placed with equal partition on the base unit 4. The number of straps 9 and their placement are adapted to size of the boxes 5 and the number of boxes 5 in each layer. Thus, a base unit 4 is formed that may be used as a stabilizing unit for a unit load 1. A person skilled in the art real- izes that also lower corner boards may be used. Such possible lower corner boards are normally placed between the base mat 3 and the loading ledges 2. That person also realizes that depending on the sensitivity of the boxes 5 base units having no corner boards may also be formed. Thus, it is possible to adapt the base unit to the actual need in each specific case.

A unit load 1 is formed by placing a number of further layers of boxes 5 on top of the base unit 4. In the embodiment of Fig. 1 the unit load 1 consists of one base unit 4 and seven further layers of boxes 5. The edge protections 8 go along the total height extension of the unit load 1. The edge protections 8 are preferably made of a relatively soft plastic material but may also be made of a rather stiff material. In addition to the protective func- tion the edge protections 8 assist in stabilizing the unit load 1, especially if rather stiff edge protections 8 are used. In other embodiments there are no edge protections. A number of further straps 9 are used in forming of the unit load 1. In alternative embodiments the loading ledges are fixed to the boxes by means of adhesive or by a stretch film as an alternative or a complement to the strapping. By means of the stabilizing base unit 4, the straps 9 and possible edge protections 8 a relatively stable unit load 1 is formed. The number of boxes 5 in each layer and the number of layers of boxes 5 in the unit load 1 may vary widely. In principle the base unit may be formed by only one box 5. When the unit load 1 is completed it will be lifted from the fixture 10 by means of a forklift, a pallet truck or the like. A person skilled in the art realizes that the dimensions, number of cups 24 etc. of the fixture 10 may be varied in many different ways, depending on the design and form of the loading ledges to be used and of the boxes 5 forming the unit load 1. The fixture 10 may also be used even if no specific base unit is formed. It is also possible to form the base unit 4 and, thus, the unit load 1 without the use of a fixture.

In other embodiments beams 31 or the like connecting opposite loading ledges 32 are used instead of the base mat as support part. One example of such an embodiment is shown in Fig. 9. In this embodiment the bottom of the base unit is formed of four loading ledges 32 placed to give a generally rectangular form. A person skilled in the art realizes that the dimensions of the rectangle formed and the length of the loading ledges 32 forming said rectangle are dictated by the size of the boxes or the like which are to form a unit load. In other embodiments loading ledges are placed giving a quadratic form. Two beams 31 are placed with the ends supported on the loading ledges 32 on the longer sides of the base unit and parallel with the other loading ledges 32. The beams 31 each have a generally inverted T-form. In one embodiment the beams 31 are made of two corner boards brought together. The beams 31 are placed so that the boxes or the like are received supported at one end by the beams. The beams 31 will stabilize the rectangle formed by the loading ledges 32. A person skilled in the art realizes that the beams 31 may have many different designs and orientations, as long as they fulfill a stabilizing function. In this example lower corner boards 7 are re- ceived on the loading ledges 32. The first layer of boxes is placed on the corner boards 7 on the loading ledges 32 and on the beams 31 to form a base unit, comparable with the base unit described above. Thus, straps 9 or the like, corner boards 6, 7, 20 and possible edge protections 8 are used in forming the base unit on which further layers of boxes are placed to form the unit load.

Also in this case a fixture 33 may be used in forming the base unit and the unit load. Said fixture 33 has a generally rectangular form, with two long sides 34 and two short sides 35. Cups 24 are formed on all four sides 34, 35 of the rectangle to receive loading ledges 32 on all four sides 34, 35. Thus, in this case the formed base unit will have loading ledges 32 on all four lower edges. Furthermore, also in this embodiment shown in Fig. 10 a middle brace 36 is arranged between the long sides 34. A person skilled in the art realizes that this fixture 33 may also be used for base units and/or unit loads having loading ledges 2, 11, 12, 32 on only two opposite lower sides.

Irrespectively of the form of the base unit and the unit load a possible fixture has to be adapted to the number and placement of the loading ledges used in forming the base unit and the unit load.

Claims

1. A method of forming a unit load comprising a number of boxes in several layers and at least two loading ledges at two opposite lower sides of the unit load, char- acterizβd m that the lowermost layer of boxes placed on the loading ledges is formed into a separate, stabilizing base unit and that the other layers of boxes are placed on the base unit after the forming of the base unit.

2. The method of claim 1, characterized in that cor- ner boards are placed at the lower edges of the layer of boxes of the base unit, at the upper edges of the layer of boxes of the base unit and/or between boxes of the base unit .

3. The method of claim 2, characterized m that one or more stabilizing parts are placed on the loading ledges before the lowermost layer of boxes is received and that straps and/or stretch film are wound around the loading ledges, the stabilizing parts, the lowermost layer of boxes and the possible lower and upper corner boards to form the base unit.

4. The method of claim 1 or 2, characterized in that the loading ledges are attached to the layer of boxes of the base unit by an adhesive.

5. The method of claim 1, characterxzed in that the loading ledges are placed in a fixture before forming the base unit.

6. A stabilizing base unit (4) to be used in the forming of a unit load (1) , characterized in that it consists of boxes (5) placed in one layer, at least two load- ing ledges (2, 11, 12, 32) placed at two opposite lower sides, one or more stabilizing parts placed on the loading ledges (2, 11, 12) below the layer of boxes (5) and means to hold the base unit together.

7. The base unit (4) of claim 6, characterized in that the means to hold the base unit (4) together is one or more straps (9) and/or stretch film surrounding the loading ledges (2, 11, 12, 32) and the boxes (5) of the base unit

(4) and/or an adhesive placed between the loading ledges

(2, 11, 12, 32) and the layer of boxes (5) .

8. The base unit of claim 6, characterized in that the stabilizing part is formed of a base mat (3), that the base mat (3) is of wood and/or that the base mat (3) has a rectangular form with struts (19) positioned to receive boxes ( 5 ) .

9. The base unit of claim 6, characterized in that the base unit has four loading ledges (32), placed on all four lower sides of the layer of boxes (5) .

10. The base unit of claim 6, characterized in that the base unit has four loading ledges (2) placed on two op- posing sides and/or that the loading ledges (2) partly overlap at the middle of each opposing side.

11. The base unit of claim 6, characterized in that it comprises corner boards (6, 7, 20) placed at the top edges of the layer of boxes (5) of the base unit (4), at the bottom edges of the layer of boxes (5) of the base unit (4) and/or between boxes (5) of the base unit (4) and/or that it further comprises vertical edge protections (8) placed at the corners of the base unit (4) .

12. The base unit of claim 6, characterized in that the stabilizing part is formed of beams (31) placed between opposite loading ledges (32), that the beams (31) have a T- form and/or that the beams (31) are positioned to support at least one lower edge of each box (5) .

13. A fixture (10, 33) to be used in the forming of a unit load (1), characterized in that it comprises a rectangular frame formed of four bars and cups (24) to receive at least two feet (15, 16) of at least two loading ledges (2, 11, 12, 32), which cups (24) are placed on at least two of the bars.

14. The fixture (10) of claim 13, characterized in that the rectangular frame formed of the four bars has two long sides (22) and two short sides (21) and that four cups (24) are arranged on each long side (22) with one cup (24) at each end of the long side (22) and two cups (24) at the middle of the long side (22) at a small distance from each other.

15. The fixture (10) of claim 14, characterized in that the distance between the two cups (24) in the middle of each long side (22) is about the same as the width of a brace (23) placed between the long sides (22) of the fixture (10) and between the two cups (24) in the middle of each long side (22) .

16. The fixture (10) of claim 14, characterized in that a plate (30) is arranged to assist in fixation of the short sides (21) to the long side (22) and,,_,that the fixation is accomplished by means of screws (29) , rivets, welding, soldering, gluing etc.

17. The fixture (33) of claim 13, characterized in that the rectangular frame formed of the four bars has two long sides (34) and two short sides (35), that at least three cups (24) are provided on each side (34, 35) of the fixture (33), that one cup (24) is placed at each end of each side (34, 35) and that one cup (24) is placed approxi- mately in the middle of each side (34, 35) between the cups (24) at the ends of the sides (34, 35) and that a brace (36) is placed between the long sides (34) .

18. The fixture (10, 33) of claim 13, characterized in that the four bars forming the rectangle have beveled parts (27, 28) .

19. The fixture (10, 33) of claim 13, characterized in that the cups (24) are made of several parts (25, 26), that one cup part (25) has three sides and/or that the cups (24) have a generally rectangular form with inclined sides, the inclination widens upwards.

20. The fixture (10, 33) of claim 13, characterized in that the cups (24) are placed to receive feet (15, 16) of loading ledges (2, 11, 12, 32) when forming a base unit and/or a unit load and/or that the fixture (10, 33) is made of plastic, aluminum or other suitable metal.