Receptacles – Sectional – Folding
Reexamination Certificate
1997-05-06
2001-01-09
Moy, Joseph M. (Department: 3727)
Receptacles
Sectional
Folding
C217S048000, C217S045000
Reexamination Certificate
active
06170688
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to crates for packaging items such as generators, appliances, and tubs and, more particularly, to methods and apparatus for packaging such items in crates.
BACKGROUND OF THE INVENTION
Many items fabricated or assembled at a plant must be packaged for shipment upon completion of the fabrication or assembly processes. Although such packaging is necessary, the time and costs associated with packaging items do not relate directly to the manufacture of core products. Therefore, in an effort to maintain a focus on core product production, many manufacturers seek to reduce the time and costs associated with packaging so that resources can be directed to the core manufacturing activities.
Corrugated boxes are well known and facilitate reducing the packaging time and costs. Specifically, such boxes generally are not expensive and are easily and quickly assembled. Although corrugated boxes provide some protection against damage for some items, such boxes lack the strength and rigidity needed for heavy items such as appliances. In addition, such boxes generally are not reusable and are discarded after one delivery.
With heavier items such as heavy machinery (e.g., generators), fragile items, and appliances, such items typically are built on pallets and then upon completion of the manufacturing process, a crate is built around the items using the pallet as a base. For example, and with respect to a generator, the generator typically is assembled on a pallet and upon completion of the generator assembly process, crate side units are stapled (e.g., using a staple gun) to the pallet and to each other. A top may then be located over the side members and stapled to the side member edges. Crates fabricated in this manner have been used for many years.
Typically, and to increase productivity, two workers having staple guns assemble the crate. At various times during the crate assembly process, one worker will be shooting staples into the pallet in a direction toward the other worker. Of course, workers recognize the hazard and wear protective clothing and eye protection. In spite of the precautions and protection measures, having one worker shoot staples in the direction of another worker remains hazardous and it would be desirable to eliminate this situation. In addition, having workers assigned to building such crates is expensive in terms of labor costs. Further, since staples are used in the assembly process, such crates generally are not reusable and typically are discarded after one delivery.
In an attempt to reduce at least the labor costs associated with assembling crates, a known crate subassembly includes four side units preassembled and interconnected using nylon straps. The nylon straps are used so that the side units can be easily and quickly arranged around a pallet. While this known subassembly does provide some advantages, the subassembly is flimsy and may collapse on a worker when attempting to position the subassembly around a pallet. In addition, some stapling must be done in order to secure the subassembly to a pallet. The known subassembly also is not reusable and typically is discarded after one delivery.
Accordingly, it would be desirable to provide methods and apparatus which enable safe, easy, and fast assembly of sturdy and reusable crates. It also would be desirable to provide a crate subassembly which is low in cost and does not easily collapse during assembly.
SUMMARY OF THE INVENTION
These and other objects may be attained by a crate which includes a crate subassembly constructed in accordance with the present invention. Particularly, in one aspect, the present invention relates to a crate subassembly including four side units, and each side unit has a top cord, a bottom cord, and vertical cords extending between and secured to the top and bottom cords. The top cord and bottom cord of each side unit extend substantially parallel to each other, and each side unit further includes a diagonal cord extending from and connected to the top and bottom cords.
Connector plates are located to connect the respective adjacent vertical cords of each side unit. More particularly, on the inner surface of the subassembly, connector plates extend across the interfaces between adjacent vertical cords, and across the interfaces between vertical cords, top cords, bottom cords, and diagonal cords. In addition, a free end connector plate is located over and extends from the top cord of one end side unit, and a free end connector plate is located over and extends from the bottom cord of the other, opposing end side unit. Additional connector plates are located at the subassembly outer surface and extend across interfaces between vertical, diagonal and top cords, and across interfaces between vertical, diagonal and bottom cords. On the outer surface of the subassembly, however, no connector plate extends over the interface between adjacent vertical cords.
The arrangement is then located under a press, and the press is operated to embed the connector plates into the cords so that the connector plates partially extend into and securely engage the cords. The press is then withdrawn, and the end side units are folded over the intermediate side units until the end units are resting over the intermediate side units. In this position, the free end connector plates extend across the interface between the now adjacent vertical cords of the respective end units. The press is then again operated to press the folded subassembly so that the free end connector plates securely engage adjacent cords to complete fabrication of the subassembly.
For storage, many subassemblies can be stacked over each other in the folded condition to save space. When it is desired to form a crate, a subassembly can be removed from the stack and easily and quickly opened. More particularly, by simply separating opposing side units, the subassembly is opened. When opening, the connector plates on the inner surface of the subassembly flex, or bend, and the connector plates have sufficient rigidity so that once opened, the subassembly does not close on itself during handling. With the subassembly in the open condition, the subassembly is readily secured to a pallet using, for example, screws.
The above described subassembly enables safe, easy, and fast assembly of sturdy and reusable crates. In addition, such subassembly is low in cost and does not easily collapse.
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Armstrong Teasdale LLP
MiTek Holdings, Inc.
Moy Joseph M.
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