WO2021117012A1

WO2021117012A1 - Stackable storage crate

Info

Publication number: WO2021117012A1
Application number: PCT/IB2020/061858
Authority: WO
Inventors: Andrew Gunn
Original assignee: Banair (Holdings) Ltd
Priority date: 2019-12-13
Filing date: 2020-12-11
Publication date: 2021-06-17

Abstract

A stackable storage crate (10) comprising a plurality of vertical members (12), a foot (40) disposed on a lower end of each vertical member, a top corner (28) disposed on an upper end of each vertical member (12), said top corner (28) comprising dimensions and a shape which enables said top corner (28) to engage with another foot so as to inhibit movement of the another foot in at least two dimensions, a pair of front and rear top frame members (16) with a plurality of top joists (20) disposed thereon, a pair of front and rear bottom frame members (14) with a plurality of floor joists (18) disposed thereon, and a pair of fork tubes (22) arranged at least substantially perpendicular with and disposed under said pair of front and rear bottom frame members (14).

Description

CARGO STACKING CRATE SYSTEM AND METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of the filing of U.S. Provisional

Patent Application No. 62/947,718, entitled "Cargo Stacking Crate System and Method", filed on December 13, 2019, and the specification thereof is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] Military air cargo presents different challenges from that of commercial air cargo.

Commercial cargo storage and handling is highly optimised with predictable schedules and cargo volumes. Consequently, airports have evolved complex and efficient solutions to store and handle their freight. Military air cargo operations are not as regular and predictable, and therefore require much more flexibility in the storage and handling arrangements. Missions change frequently, requiring sites to adapt to changing requirements rapidly. This presents significant challenges to logisticians designing their ideal cargo storage facilities as the design goal is a moving target. Typically, therefore, cargo is simply stored on the ground, so that loads can be stored densely as bulk, or in accessible "parking lot” type rows. As the space required to store such large loads is high, often such cargo is stored outside where it is exposed to weather. Alternatively, when it is stored indoors the volumetric space of hangars or warehouse buildings is not maximized.

[0003] Storage systems for heavy loads such as air pallets, which can typically weigh up to

12,000lbs each, are normally constructed from heavy duty steel uprights and platforms which are all bolted to each other to create large-scale racking systems. Such systems require significant installation works, often with dedicated foundations required, and are therefore not easily reconfigurable. Due to this inflexibility, military planners avoid such largescale structures as not meeting operational needs.

[0004] Aside from dedicated air pallets, cargo (for example wooden crated components, palletized goods, and other crated materials) is typically stored as bulk cargo in warehouses, with items stacked on top of themselves. Designing racking systems to store small crates, large crates, short/long items, light/heavy items, all within the same rack system with lots of load variety is very challenging, hence items are just stored in bulk. Taking this bulk approach imposes limits on how many items can be safely stacked, resulting in under-utilized volumetric space in buildings. One solution to this is to install secondary flooring in buildings - mezzanines - which allow flexible use of area, and better use of volume, typically with lighter items stored on the upper floor. However, their design and construction are again very site spr - ' lot flexible. They also prevent buildings such as hangars from being easily repurposed back to open space, since to do so requires a complicated disassembly process.

[0005] Cargo which is moved by air is typically of a higher strategic value to the military than cargo which travels by surface, whether this is due to time or the important nature of the specific cargo items (e.g., food may be a critical cargo where it is required to be moved rapidly to destinations, whereas when time is not pressing it can be moved much more effectively by road/rail/sea). At military air facilities, cargo is often stored outside either because it is imminently to be transported, or because no other space may be available. During this time outside, that same strategically important cargo is exposed to weather (sun, rain, snow), as well as potential enemy observation in terms of overhead surveillance by satellite or spy planes.

[0006] Military logisticians can benefit from a solution that allows them to stack cargo effectively, but without the need for permanent inflexible storage layouts.

[0007] Examples of known portable stacking solutions for large cargo with weather protection is scarce. Much smaller metallic crates exist commercially in a myriad of configurations for storing all types of standard and bespoke loads. They are designed to stack several units high and can be moved by forklift. They are invariably welded constructions designed for a dedicated purpose, bulky to transport, making shipping a large number of them for a storage project difficult. However, such known welded systems cannot accommodate full air cargo pallets, up to 12,000lbs and up to 108 x 88 x 96in in size.

[0008] At the size and scale needed to accommodate fully loaded air pallets, a rigid welded construction would result in a crate that is not reasonably able to be transported from the factory to the customer (especially for a large-scale deployment that requires several such welded creates to quickly be transported great distances and put in use in short order). Nor could the crates thereafter be easily moved from one site to another one or more sites as a mission progresses. Still further, such welded units would not be adjustable and thus would not be able to flexibly adapt to changing demands in the cargo storage system. An entirely different design and construction approach is thus needed.

[0009] Methods of storing large air cargo typically involve multi-level steel-framed storage systems, often with integrated craneage. Design and construction of such facilities are complex, site- specific, and are not moveable or deployable according to need. They can perform defined storage tasks very efficiently. However, known storage systems do not adapt to changing needs and missions. The large investment required to create such a structure at a first site cannot often be justified if it is only a temporary facility, and especially where operations are predicted later to move to one or more other sites. The challenge in justifying such large-scale cargo storage investments is often the reason why they do not get installed and are typically only found at strategic air base locations, rather than at satellite or remote sites.

[0010] There is thus a present need for a heavy-duty stacking crate that does not require permanent anchoring in place, but which is modular and moveable. There is further a present need for a system which allows cargo to be stored outside under integrated fabric covers so that it is protected from the worst weather and is disguised from view, so as to protect the strategically important cargo.

[0011] Outside of dedicated air facilities there is still a requirement to store and protect cargo, e.g., for remote storage locations and expeditionary airfields where the sites have yet to have buildings constructed. For such sites, there may not be hard-stand (e.g., concrete or asphalt) available to store cargo on, thus leaving it vulnerable in the open to both the weather and ground conditions (e.g. mud). Thus, there is a need for a system that incorporates ground supports that allow it to be sited on unimproved ground and, when combined with fabric covers, allows cargo to be sited outside protected from weather and ground conditions.

[0012] Note that the following discussion refers to a number of publications by author(s) and year of publication, and that due to recent publication dates certain publications are not to be considered as prior art vis-a-vis the present invention. Discussion of such publications herein is given for more complete background and is not to be construed as an admission that such publications are prior art for patentability determination purposes.

BRIEF SUMMARY OF EMBODIMENTS OF THE PRESENT INVENTION

[0013] An embodiment of the present invention relates to a stackable storage crate having a plurality of vertical members, a foot disposed on a lower end of each vertical member, a top corner disposed on an upper end of each vertical member, the top corner having dimensions and a shape which enables the top corner to engage with another foot so as to inhibit movement of the another foot in at least two dimensions, a pair of front and rear top frame members with a plurality of top joists disposed thereon, a pair of front and rear bottom frame members with a plurality of floor joists disposed thereon, and a pair of fork tubes arranged at least substantially perpendicular with and disposed under the pair of front and rear bottom frame members.

[0014] Optionally, the top corner can include comprises a lug and the foot can include an opening having dimensions that can receive the lug. The plurality of top joists can include at least four top joists. The plurality of floor joists can include at least four floor joists. The stackable storage crate can also include a shelf. In one embodiment, the foot can include a standardized ISO casting that allow the crate to be locked down to a surface - for example by using one or more twist-lock fasteners. The stackable storage crate can als^~ quide plates disposed above the front and rear bottom frame members. The front and rear bottom frame members can be are attachable to the plurality of vertical frame members via a bolted connection. In one embodiment, the front and rear top frame members are optionally not welded to the plurality of vertical frame members. The pair of fork tubes can be attached to the pair of front and rear bottom frame members via one or more bolts.

[0015] Embodiments of the present invention also relate to a stackable storage crate having a plurality of vertical members, a foot disposed on a lower end of each vertical member, a top corner disposed on an upper end of each vertical member, the top corner having dimensions and a shape which enables the top corner to engage with another foot so as to inhibit movement of the another foot in at least two dimensions, a pair of front and rear top frame members with a plurality of top joists disposed thereon, a pair of front and rear bottom frame members with a plurality of floor joists disposed thereon, and the pair of front and rear top frame members configured to attach to a plurality of vertical members via one or more bolts.

[0016] The plurality of top joists can be configured to attach to the pair of front and rear top frame members via one or more bolts. The plurality of floor joists can be configured to attach to the pair of front and rear bottom frame members via one or more bolts. In one embodiment, the plurality of vertical members are not welded to the pair of front and rear top frame members.

[0017] The stackable storage crate can also include a covering. The covering can be configured to attach to an internal area of the crate. The covering can be configured to cover a top and three sides of an internal area of the crate. The stackable storage crate of can also include a shelf. A plurality of openings can be disposed in the plurality of vertical members. The shelf can be adjustably positionable within the crate by bolting the shelf to the plurality of vertical frame members at a selection of the plurality of openings.

[0018] Embodiments of the present invention provide a flexible and heavy-capacity crate system for cargo storage that allows for easy user reconfiguration and adaptation to changing needs. Embodiments of the present invention preferably use multiple steel components which bolt or otherwise fasten together to create a stackable storage crate for air cargo and other bulky cargo and/or commodities.

[0019] In one embodiment, the bolted assembly method preferentially reduces shipping volume such that transportation to the point of use can be optimized, with the crates being assembled on site for use. Such a simplification applies to all the embodiments of the invention.

[0020] According to a further embodiment of the invention, the crate benefits from fork pockets at the base, allowing the crate to be lifted by forklift whether empty or with items stored within. [0021] According to one embodiment of the invention, the construction of the crate provides stacking hardware at the top and bottom such that the crate can be safely stacked and avoid lateral movements which would otherwise displace the correct stacking position. The uprights can feature additional securing methods, structures, and/or apparatuses, which can include, for example, holes to support intermediary shelves being added to the crate, thus providing more storage utility to the user in allowing further compartment permutations to adapt efficiently to their application.

[0022] As an additional feature, the storage positions in the crate can present integrated dunnage, allowing flat bottomed pallets or cargo to be positioned within the crate, whilst also allowing the forklift tines to be withdrawn after positioning, such a feature providing more versatile storage combinations for the users.

[0023] Furthermore, the crate can feature anchoring positions for covers to be fitted to the crate, which allows cargo stored within the crate to be protected from weather and environmental factors and allows the crate to be used flexibly inside and outside. Preferably, the crate can be finished with rugged surface treatments that can include, for example, hot-dip galvanizing, thus allowing permanent outdoor use and as an additional feature of this invention, the crate can comprise multiple drainage holes/slots allowing such dip galvanization to take place.

[0024] As an additional feature of the invention, the crate can be fitted with side alignment plates, thus allowing cargo to be squared into the correct placement during loading and unloading, with such a feature making operation of the crate easier - especially for larger cargo loads, which can include, for example, containers.

[0025] Objects, advantages and novel features, and further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0026] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more embodiments of the invention and are not to be construed as limiting the invention. In the drawings: Fig. 1 is a drawing which illustrates an elevated perspective view of an assembled crate according to an embodiment of the present invention;

Fig. 2 is a drawing which illustrates a front view of a crate according to an embodiment of the present invention;

Fig. 3 is a top elevation view drawing which illustrates a crate of an embodiment of the present invention;

Fig. 4 is a side view drawing of a crate according to an embodiment of the present invention;

Fig. 5A is a drawing which illustrates disassembled components of a crate according to an embodiment of the present invention;

Fig. 5B is a drawing which illustrates a close-up view of a top corner of a crate to show the connection assembly of upper frame members to tab

Figs. 6A and 6B are drawings which respectively illustrate an add-in shelf and the components that can be used to create the add-in shelf according to an embodiment of the present invention;

Fig. 7 is a drawing which illustrates how on crate can support two full sized cargo loads;

Fig. 8 is a drawing that illustrates how a load can be placed on top of a crate.

Fig. 9 is a drawing which illustrates how a crate can be lifted by a forklift while containing a load;

Figs. 10A, 10B, and 10C respectively illustrate a top crate being placed onto a bottom crate, a stacked assembly of two crates, and a close-up view of a pair of top and bottom mating corners of a pair of crates;

Fig. 11 is a drawing which illustrates a pair of crates placed side by side and wherein each crate holds a cargo load inside of it and wherein the pair hold oversized items across the top of them;

Fig. 12 is a drawing which illustrates a plurality of crates loaded onto a semitrailer for transport and wherein each crate has a load stored inside.

Fig. 13 is a drawing which illustrates a single bottom layer of crates stacked together with loads disposed therein and with loads disposer' ^{~~ x} - 'the them; Fig. 14 is a drawing which illustrates a plurality of crates being stacked together in two layers;

Figs. 15A and 15B are drawings which respectively illustrate an internal covering system being installed into a crate and the completed crate with the internal covering system installed;

Figs. 15C and 15D are drawings which respectively illustrate another embodiment of an internal covering system being installed into a crate and the completed crate with the internal covering system installed;

Fig. 15E is a drawing which illustrates a side-view of a crate with a panel front panel disposed near but not on the crate;

Fig. 15F is a drawing which illustrates a close-up view of a corner of a crate with a side covering disposed near but not installed on the crate;

Fig. 15G is a drawing which illustrates a close-up view of a corner of a crate with a side covering disposed on the crate;

Fig. 15H is a drawing which illustrates a top of a crate with a top cover installed thereon;

Fig. 16A illustrates a crate with an internal shelf positioned down low;

Fig. 16B illustrates a crate with an internal shelf that is positioned at a higher location than is illustrated in Fig. 16A; and

Figs. 17A, 17B, and 17C are drawings which respectively illustrate front and perspective views of different loads in and on a crate and which illustrates a crate with a shelf disposed at a higher location and with items disposed in and on the crate.

DETAILED DESCRIPTION OF THE INVENTION

[0027] Referring now to the figures, in one embodiment, crate 10 is preferably formed from a plurality of vertical members 12 which span between front and rear bottom frame members 14 and front and rear top frame members 16. Floor joists 18 preferably rest upon and are connected to front and rear bottom frame members 14. Top joists 20 preferably rest up on and are connected to front and reartop frame members 16. Floor joists 18 preferably support loads placed within an interior of crate 10 while top joists 20 preferably support loads placed atop crate 10. Although the number, spacing, and configuration of floor joists 18 and top joists 20 can optionally be adjusted to accommodate any desired load, in one embodiment, four floor joists 18 and four top joists 20 are preferably provided. Floor joists 18 and top jor^{x ~ ~} preferably spaced so that they easily accommodate forks of a forklift, without requiring the forks to be shoved together to load and unload crate 10.

[0028] Fork tubes 22 are preferably disposed on an underside of front and rear bottom frame members 14 and are spaced to receive forks of a forklift. Guide plates 24 are preferably disposed on inside sides of crate 10 so that when a load, for example a pallet, is slid into crate 10, it is guided back without encountering vertical members 12 or reinforcing members 26. In one embodiment, guide plates 24 are preferably disposed on a lower internal portion of crate 10.

[0029] Reinforcing attachment tabs 27 are preferably disposed on vertical members 12 - most preferably via welding. Attachment tabs 27 preferably include one or more openings through which a fastener is used to connect an end portion of a reinforcing member 26.

[0030] Top corners 28 can optionally be formed from an ISO corner casting and/or can be constructed to accommodate or otherwise interact with international standardization organization (“ISO”) corner castings. For example, in one embodiment, Top corners 28 can include side plate 30, front and/or rear plate 32, and lug 34. Lug 34 preferably comprises dimensions that permit it to fit within an opening of an ISO corner casting.

[0031] Bottom feet 40 are preferably provided. In one embodiment, ISO corner castings can be used as bottom feet 40. In this embodiment, bottom feet 40 preferably comprise one or more openings 42. Although the figures show openings disposed on one or more sides of feet 40, in one embodiment, the opening 42 can also be disposed on a bottom of each foot 40. Most preferably one of the one or more openings 42 is preferably disposed on a bottom of bottom feet 40 such that when a second crate is stacked upon a first crate, lugs 34 that project up from the top corners of the bottom crate fit up into openings 42 which are on the bottom of bottom feet 40 of the top crate. Thus, top corners 28 plug into bottom feet 40 to help hold a top crate onto a bottom crate such that the top crate does not slide off of the bottom crate. This configuration enables a forklift operator to simply place a top crate onto a bottom crate and lift it off when needed without performing manipulations to secure the top crate to the bottom crate (see Figs. 10A and 10B and the detail view of Fig. 10C).

[0032] A plurality of openings 46 are preferably disposed in vertical members 12. Openings

46 preferably accommodate fasteners that are used to secure shelf 50 (see Figs. 6A, 6B, 16A, 16B and 16C). Most preferably openings 46 are arranged as a row of several openings such that shelf 50 can be attached to vertical members 12 at any of several different mounting heights to accommodate various sizes of loads that will be placed on or under shelf 50. For attachment, shelf 50 preferably comprises ends 52 which each preferably comprise a pair of L or T-shaped brackets which comprise one or more openings 54. Optionally, a single piece of material can be bent, cast, or otherwise formed such that the L or T-shaped bracket is formed to have two L or T-shaped plates disposed a distance from one another. The L or T-shaped ' - are spaced apart by a distance sufficient to accommodate the width of vertical members 12 such that when installed, a vertical member 12 is disposed between the pair of L or T-shaped brackets and fasteners can be passed through openings 54 of ends 52 and through openings 46 of vertical members 12. Although any desired fastener can be used, in one embodiment, the fasteners preferably comprise bolts and/or pins.

[0033] Although various frame members can each be formed from a single member, in one embodiment, as best illustrated in Fig. 5B, one or more, or even all, of the frame members of crate 10 can be formed from a plurality of frame members. For example, a pair of top front or rear frame members can be sandwiched together to form a single front or rear frame member 16. As best illustrated in Fig. 5B, vertical members 12 preferably comprise mounting plate 21 affixed thereto - most preferably mounting plate 21 is welded to vertical members 12. Mounting plate 21 preferably comprises openings 23 disposed therein. In constructing crate 10, a front or rear top frame member 16 can be formed by placing a pair of them back-to-back and sandwiching plate 21 between them and then passing bolts through openings of the frame members and through openings 23 in plate 21. In one embodiment, each of front and/or rear frame members 16 are preferably constructed and attached to a vertical member 12 by placing a pair of channel beams back-to-back and sandwiching a tab of a vertical member 12 between them. Although Fig. 5B shows this configuration for a single rear top frame members 16, this construction configuration can be used for one or more or even all of front and rear top frame members 16, front and rear bottom frame members 14, upper side members 17, and/or lower side members 19.

[0034] As best illustrated in Fig. 6B, shelf 50 is preferably formed from a pair of support rails

56. Each shelf 50 also preferably comprises a plurality of shelf joists 60. To assemble shelf 50, shelf joists 60 are preferably placed atop support rails 56 and secured thereto - most preferably via a plurality of fasteners, which most preferably comprises nuts and bolts. Ends 52 are preferably include tab 58 which engages support rails 56 and a plurality of fasteners are preferably used to secure tab 58 of each end 52 to a respective end portion of support rails 56. As previously discussed, support rails 56 can be formed from a plurality of individual component pieces, for example channel members which can be placed back-to-back to form a single support rail 56. Thus, tab 58 of end 52 can be disposed between the individual component pieces and sandwiched therebetween - most preferably by bolting the individual component pieces back-to-back with tab 58 sandwiched therebetween.

[0035] Of course, shelf 50 can be constructed in any other known manner - for example in one exemplary alternative embodiment, support brackets can be welded along the inside side of support rails 56 and shelf joists 60 can be secured to those support brackets.

[0036] As best illustrated in Fig. 5A, vertical members 12 most preferably include a top corner 28 and a bottom foot 28, as well as a pair of attachment tabs 27. Openings are preferably disposed in front and rear bottom frame members 14, front and rear top frame members 16, floor joists 18, top joists 20, upper side members 17 ' — r side members 19, and fork tubes 22. This enables all of the various members to be stacked together in a compact disassembled configuration and shipped to a destination where they can be easily assembled with fasteners. This enables numerous crates 10 to be shipped in a highly compact configuration.

[0037] The overall length, width, and height of crate 10 can be constructed to be any desirable size or any combination of sizes. However, in a most preferred embodiment, crate 10 preferably comprises dimensions that accommodate a 463L master pallet and/or (type ISU 60/70/90 containers), placed in or on crate 10, which can include for example internal dimensions of at least about 116 inches (294.64cm) by 94 inches (238.76cm) by 104 inches (264.16cm). In one embodiment, crate 10 is preferably configured to accommodate a load of at least about 12,000 pounds placed on floor joists 18 and a load of at least about 12,000 pounds placed on top joists 20, without any of the various members that are used to form crate 10 experiencing plastic deformation.

[0038] As best illustrated in Figs. 15A and 15B, in one embodiment, covering 70 can be provided. Covering 70 preferably includes a top and three sides. In addition, because only three sides are preferably provided by covering 70, the front portion of the internal area of crate 10 is also left exposed. This enables cargo to be loaded into and extracted from crate 10 without requiring a user to open and close covering 70, and yet, the cargo can remain relatively dry because its top and three sides are protected by covering 70. In this embodiment, covering 70 is preferably configured to fit onto Crate 10 such that a back and side portions of covering 70 pass over an outside portion of crate 10 while a top portion of covering 70 rests up inside of crate 10, against the inner top portion of crate 10. Thus, the top of covering 70 is not on top of an exterior of crate 10, which would likely cause the cover to be torn when loading cargo on top of crate 10. In addition, the side portions of covering 70 are not inside of crate 10, which would also likely result in the sides being torn when cargo is slid into and out of crate 10. Thus, when covering 70 is installed in crate 10, bottom floor joists 18 are exposed inside the partial enclosure formed by covering 70. Although covering 70 is preferably made from a flexible fabric material (for example a tarp material) in one embodiment, covering 70 can optionally be made from another material, including but not limited to waterproof rigid panels.

Although in one embodiment, covering 70 preferably only covers three internal sides of crate 10, in one embodiment, covering 70 can be configured to cover all four sides of an internal area of crate 10 (for example, covering 70 can be made to flap open or otherwise roll up to expose a front portion of an internal area of crate 10 to allow cargo to be loaded into and out of crate 10).

[0039] Within crate 10, there are preferably a multitude of anchoring points to which covering

70 can be affixed to provide environmental protection for loads. For example, any of the various frame and/or joist members of crate 10 can include one or more holes disposed therein to that covering 70 can be connected to. Optionally, covering 70 can be added to and/or removed from crate and/or can be installed on crate 10 at the time that crate 10 is constructed. In one embodiment, covering 70 can include a plurality of eyelets and/or grommets which can be used to tether covering 70 to various openings in crate 10. Optionally, ' - a plurality of straps can be affixed to or otherwise formed onto covering 70 such that the straps can be tied to crate 10 through the various openings provided therein and/or around the various frame members and joists thereof.

[0040] Although covering 70 can be formed as a single covering that covers a top and more than one side, in one embodiment, as best illustrated in Figs. 15C - 15H, covering 70 can be formed from a plurality of individual panels, which themselves can optionally be flexible panels, rigid panels, and/or a combination thereof. For example, top panel 17 can be configured to be disposed at an inside top portion of crate 10. Rear panel 72 can be configured to be disposed on a back of crate 10. Side panels 73 can be disposed on an inside side of crate 10. Front panel 74 can be disposed on a front portion of crate 10. Optionally, top panel 72 can comprise sides 76 which extend downward when top panel 72 is disposed in its intended position within crate 10. Optionally, one or more fasteners 78 can be disposed on or about any of the panels.

[0041] In one embodiment, fasteners 78 can be disposed on sides 76 of top panel 71, and/or on one or more sides of any other covering panels 72, 73, and/or 74. In one embodiment, side panels 73 can attach to rear panel 72 and/or front panel 74 via a plurality of fasteners 78 which preferably pass around an outside of one or more vertical members 12 and engage with a mating fastener 78. Although fasteners 78 can be formed from any desired fastening system, apparatus, or component, in one embodiment, fasteners 78 preferably comprise clips, which are most preferably connected to the respective panel via a strap 79, which can include any elongated connecting member, including but not limited to a strap, rope, cord, chain, cable, tether and/or combination thereof. Optionally, one or more of panels 71, 72, 73, and/or 74 can be attached to one or more locations of crate 10 via one or more fasteners 80, which can include nuts, bolts, screws and/or other fasteners.

[0042] Embodiments of the present invention offer a set of unique capabilities. Crate 10 allows air cargo to be stacked vertically, several high to optimize volumetric space. Because crate 10 can be moved with a forklift and does not require bolting to the floor, military logisticians can rapidly reconfigure storage arrangements simply by moving the crates around. For instance, bulk storage layouts (for example densely packed crate arrangements) can be converted to selective accessible rack-type layouts (for example a parking lot configuration) simply by moving the crates with forklifts. Furthermore, using covering 70, permits crates 10 to be stored outside with added weather protection from the elements without the need to tediously tarp and un-tarp individual pallets.

[0043] Turning to the embodiment illustrated in Figs. 1-4, there is shown a multitude of components, which are shown disassembled in Fig. 5A. These components are preferably easily assembled, without welding, to create crate 10. Fig. 5A illustrates the individual components in their unassembled state, which can be shipped more efficiently in a compact disassembled configuration between sites. Shelf 50 can optionally be provided and can be formed from multiple components (see Figs. 6A and 6B) that can be fitted together and then added to crate 10 (see Figs. 16A-C). This allows further vertical storage compartments tc ' - ^x~ (see Figs. 17A-C). [0044] Crate 10 is preferably configured to accommodate two full sized cargo loads, one within crate 10 and the other atop crate 10 (see Fig. 7). Each of the two loads can easily be loaded onto and off of crate 10 via a forklift (see Fig. 8). Crate 10 can be lifted and moved about in either an empty configuration, or when loaded with one load in or on crate 10 or with a load in crate 10 and a load on crate 10 (see Fig. 9). This enables loads and crates to easily be moved about to change the layout of a storage area (see Fig. 14) and/or to load and unload cargo (for example into or onto a trailer (see Fig. 12), and/or to move cargo from one location to another). Multiple crates can be stacked on top of each other and crates can thereby be configured into rows to create storage structures.

[0045] When two or more crates 10 are placed side-by-side or near each other, top joists 20 can be used to store both regular loads (see Fig. 13) as well as irregular and/or long cargo items (see Fig. 11), which cargo may not otherwise fit within crate 10.

[0046] In one embodiment, crate 10 is formed of weight bearing vertical members 12, which have various brackets, tabs, feet, holes, and/or corners welded, attached, or otherwise formed thereon such that various other parts of crate 10 can attach thereto.

[0047] Although floor joists 18 and top joists 20 can be arranged in any desired orientation, in one embodiment, they are preferably arranged such that a primary axis thereof is at least substantially parallel with a primary axis of fork tubes 22 and thus preferably are arranged to extend from front to back on crate 10. This orientation permits loads without fork pockets to be placed into and/or onto crate 10 while maintaining the ability to withdraw the forks from underneath using this integrated clearance.

[0048] Because floor joists 18 are preferably arranged front to back and preferably have gaps disposed between them, this creates an integrated structural floor supports that allow flat bottomed cargo, which can include for example air pallets, to be placed into and retrieved from crate 10 by standard forklift tines. Thus, the cargo itself does not need to incorporate forklift pockets.

When crates 10 are constructed, they preferably have rigidity to be stacked vertically, with multiple units on top of each other, with no other supporting structure required, yet keeping the front and rear of the crate open for easy access to place and remove cargo from the crates. Safe stacking is ensured by using bottom feet and top corners that engage with one another to provide lateral restraint and secure the stack of crates to prevent upper crates from sliding or falling off the crate beneath it.

[0049] In one embodiment, the only portion of crate 10 which touches the surface on which it rests are bottom feet 40. There is preferably one bottom foot 40 at each of four corners of crate 10. Thus, when placed on a flat surface, the entirety of the weight exerted by crate 10 and any loads disposed thereon are preferably transmitted through the four bottom corners of crate 10. Although crate 10 is configured to apply the load to the c - ' corner castings, crate 10 additionally benefits from structural members, for example fork tubes 22 and lower side members 19, that can apply the loadings more generally across the base of crate 10, when crate 10 is placed on unimproved ground surfaces. Additionally, the corner castings permit quick and effective tethering of crates together to form rigid assemblies or impromptu racking systems that can be easily reconfigured. These features afford the possibility to use crate 10 in more unimproved or temporary storage environments. Because crate 10 can be shipped in a disassembled and highly compact form, crate 10 is optimized for transport to a destination for final assembly, thus reducing shipping volume, particularly when by shipping by containers or road transportation.

[0050] In one embodiment, crate 10 does not comprise an external covering. In one embodiment, crate 10 does not comprise solid metallic side walls. In one embodiment, after transporting crate 10 in a disassembled configuration, crate 10 is constructed by connecting the various components thereof with the use of nuts and bolts. In one embodiment, the height of a crate cannot be adjusted. In one embodiment, once constructed, crate 10 does not comprise any pivoting joints or pivoting members. In one embodiment, the various structural members that form crate 10 are not constructed from a wood material. In one embodiment, the various structural members that form crate 10 are formed from a metal material, most preferably steel. In one embodiment, fork tubes 22 are disposed below and most preferably attached to an underside of bottom frame members 14. Thus, when lifting crate 10 via fork tubes 22, the entirety of bottom frame members 14 is disposed above fork tubes 22. In one embodiment, crate 10 does not comprise a floor formed from a solid sheet of material. In one embodiment, bottom frame members 14 are longer than lower side members 19. In one embodiment, bottom frame members 14 are positioned above lower side members 19. In one embodiment, when constructed, the side having the longest length comprises the front or rear of crate 10. Thus, in one embodiment, the width (left to right) of the front of crate 10 is larger than the depth (front to back) of crate 10. In one embodiment, crate 10 does not have any components that hinge with respect to one another. In one embodiment, a top of crate 10 does not simply slide down onto vertical members 12. In one embodiment, crate 10 does not comprise wheels. In one embodiment, at least 4 floor joists 18 are provided. In one embodiment, at least 4 top joists 20 are provided. In one embodiment, each top joist 20 preferably extends all the way from a front of container 10 to a back of container 10. In one embodiment, each floor joist 18 preferably extends all the way from a front of container 10 to a back of container 10. In one embodiment, vertical members 12 do not slid into any pockets at either end thereof. Although the fork tubes 22 can comprise tubular structures, in one embodiment, fork tubes 22 need not be enclosed tubes and can instead be formed with not only open ends but also with an open side portion. Thus, in one embodiment, fork tubes 22 can comprise channel-shaped members having an open bottom and/or a pair of angle iron members positioned against or near one another to form a channel shape.

[0051] Note that in the specification and claims, “about” or “approximately” means within twenty percent (20%) of the amount or value given. [0052] Embodiments of the present invention can include every combination of features that are disclosed herein independently from each other. Although the invention has been described in detail with particular reference to the disclosed embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. Unless specifically stated as being “essential” above, none of the various components or the interrelationship thereof are essential to the operation of the invention. Rather, desirable results can be achieved by substituting various components and/or reconfiguring their relationships with one another.

Claims

CLAIMS What is claimed is:

1 . A stackable storage crate (10) comprising: a plurality of vertical members (12), a foot (40) disposed on a lower end of each vertical member; a top corner (28) disposed on an upper end of each vertical member (12), said top corner (28) comprising dimensions and a shape which enables said top corner (28) to engage with another foot so as to inhibit movement of the another foot in at least two dimensions; a pair of front and rear top frame members (16) with a plurality of top joists (20) disposed thereon; a pair of front and rear bottom frame members (14) with a plurality of floor joists (18) disposed thereon; and a pair of fork tubes (22) arranged at least substantially perpendicular with and disposed under said pair of front and rear bottom frame members (14).

2. The stackable storage crate of claim 1 wherein said top corner (28) comprises a lug (34) and wherein said foot (40) comprise an opening (42) having dimensions that can receive said lug (34).

3. The stackable storage crate of claim 1 wherein said plurality of top joists (20) comprise at least four top joists (20).

4. The stackable storage crate of claim 1 wherein said plurality of floor joists (18) comprises at least four floor joists (18).

5. The stackable storage crate of claim 1 further comprising a shelf (50).

6. The stackable storage crate of claim 1 wherein said foot (40) comprises a standardized ISO casting.

7. The stackable storage crate of claim 1 further comprising guide plates (24) disposed above said front and rear bottom frame members (14).

8. The stackable storage crate of claim 1 wherein said front and rear bottom frame members (14) are attachable to said plurality of vertical members (12) via a bolted connection.

9. The stackable storage crate of claim 1 wherein said front and rear top frame members (16) are not welded to said plurality of vertical members (12).

10. The stackable storage crate of claim 1 wherein said pair of fork tubes (22) attach to said pair of front and rear bottom frame members (14) via one or more bolts.

11 . A stackable storage crate comprising: a plurality of vertical members (12), a foot (40) disposed on a lower end of each vertical member; a top corner (28) disposed on an upper end of each vertical member (12), said top corner (28) comprising dimensions and a shape which enables said top corner (28) to engage with another foot (40) so as to inhibit movement of the another foot (40) in at least two dimensions; a pair of front and rear top frame members (16) with a plurality of top joists (20) disposed thereon; a pair of front and rear bottom frame members (14) with a plurality of floor joists (18) disposed thereon; and said pair of front and rear top frame members (16) configured to each attach to a respective pair of said plurality of vertical members (12) via one or more bolts.

12. The stackable storage crate of claim 11 wherein said plurality of top joists (20) are configured to attach to said pair of front and rear top frame members (16) via one or more bolts.

13. The stackable storage crate of claim 11 wherein said plurality of floor joists (18) are configured to attach to said pair of front and rear bottom frame members (14) via one or more bolts.

14. The stackable storage crate of claim 11 wherein said plurality of vertical members (12) are not welded to said pair of front and rear top frame members (16).

15. The stackable storage crate of claim 11 further comprising covering 70.

16. The stackable storage crate of claim 15 wherein said covering (70) is configured to attach to an internal area of said crate (10).

17. The stackable storage crate of claim 16 wherein said covering (70) is configured to cover a top and three sides of an internal area of said stackable storage crate (10).

18. The stackable storage crate of claim 11 further comprising a shelf (50).

19. The stackable storage crate of claim 18 further comprising a plurality of openings (46) disposed in said plurality of vertical members (12).

20. The stackable storage crate of claim 19 wherein said shelf (50) is adjustably positionable within said stackable storage crate (10) by bolting said shelf (50) to said plurality of vertical members (12) at a selection of said plurality of openings (46).