WO2020165662A1

WO2020165662A1 - A modular crate assembly to eliminate master box in packaging

Info

Publication number: WO2020165662A1
Application number: PCT/IB2020/050293
Authority: WO
Inventors: Pravin UPALE; Shynu Mathew
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-02-16
Filing date: 2020-01-15
Publication date: 2020-08-20
Anticipated expiration: 2021-08-16

Abstract

The present disclosure relates to the field of packaging elements. A crate assembly (100), of the present disclosure, eliminates the need of a master box, partitions and/or separators. The crate assembly (100) is modular, is ergonomical, ensures safe and easy packaging of articles, is environment friendly, and saves huge cost in supply chain system. The assembly (100) comprises a plurality of crates (110) stacked upon each other in a spaced apart configuration, and at least one support member (120) removably connected (or integral part of crate) between each of two stacked crates (110), and is configured to support a crate (110) mounted thereon. The support members (120) are push fitted on the crates (110). Recesses (130) are configured on the crates (110) to receive the support members (120) therein. The recesses (130) can be configured at corners and/or at the center of each crate (110).

Description

A MODULAR CRATE ASSEMBLY TO ELIMINATE MASTER BOX IN

PACKAGING

FIELD OF THE INVENTION

The present disclosure relates to the field of packaging elements. Specifically, the present disclosure relates to the field of crate assemblies for packaging.

BACKGROUND OF THE INVENTION

To transport any article from one place to another, it has to be securely packed before transporting. Conventionally, a palletized packaging unit is used to store articles therein for transportation. Typically, the conventional packaging unit includes a flat pallet and a master box. The flat pallet forms the base of the packaging unit and the master box forms an enclosure. The master box is placed on the flat pallet. Articles to be conveyed are placed within the unit, more specifically, in the space defined by inner walls of the master box and the flat pallet. Partitions/separators are placed in the packaging unit to define compartments within the unit. A plurality of the articles can be placed within such compartments. Once the articles are placed in the unit, the unit is strapped from all sides, stacked upon other packaging units if required, and transported to the destination. To use the articles, a user has to unpack the entire packaging unit. After taking out the articles, the packaging unit is sent for disposal. Typically, the packaging unit can be used only for one time. The conventional packaging units are typically of wood or paper. Thus, disposal of the packaging unit is hazardous to environment. Conventional wooden units require periodic fumigation to control bugs. Further, the wooden units are integral in nature and heavy in weight. It is difficult to reuse the wooden packaging units. Further, nailing is required to manufacture the wooden units. Conventional paper corrugated packaging units attract moisture in air, which reduces the strength of the unit in long sea worthy transit shipments. Thus, high grade quality moisture protective plastic sheets and desiccants/moisture absorbers are provided with the packaging units to protect them in long sea worthy transit shipments, which makes them costly. Reuse of the paper packaging units is difficult as they can only be used for lower weight applications due to reduction in their strength.

Also, to place articles in the unit, a user has to lean down multiple times to reach a lower portion of the unit, which may affect his back and health. Also, the conventional packaging units are very costly.

Therefore, there is felt a need for a crate assembly that alleviates the abovementioned drawbacks of conventional packaging units.

OBJECTS

An object of the present disclosure is to provide a crate assembly that eliminates the need of a master box.

An object of the present disclosure is to provide a crate assembly that improves work ergonomics by reducing human back pain and arm stretching fatigue caused due to bending through side walls of a conventional master box while placing and picking articles.

Another object of the present disclosure is to provide a crate assembly that is modular. Another object of the present disclosure is to provide a crate assembly that ensures safe and easy packaging of articles.

Yet another object of the present disclosure is to provide a crate assembly that is environment friendly.

SUMMARY OF THE INVENTION The present disclosure envisages a crate assembly. The crate assembly of the present disclosure is modular in nature, and eliminates the need of a master box, partitions and/or separators. The assembly comprises a plurality of crates stacked upon each other in a spaced apart configuration, and at least one support member removably connected between each of two stacked crates, and is configured to support a crate mounted thereon.

In an embodiment, the assembly comprises a plurality of support members removably connected between each of two stacked crates. Each of the crates comprises recesses configured on an operative top surface and an operative bottom surface of the crates to receive the support members. At least some of the recesses are configured at corners of the crates. One of the recesses is formed at the center of the crates.

An operative top surface of each of the crates has a shape complementary to the shape of articles to be received in the crates.

In another embodiment, the assembly comprises an array of crates stacked upon each other. Each layer of the array comprises a plurality of crates arranged abutting each other.

The assembly comprises a base pallet configured to support the stacked crates thereon. The base pallet is further configured to facilitate lifting of the stacked crate. The assembly further comprises a skirting wall configured along the periphery of the base pallet.

The assembly further comprises an enclosure configured to cover the stacked crates, and a cover mounted on the topmost layer of the stacked crates.

BRIEF DESCRIPTION OF THE DRAWING

The following figures are illustrative of particular examples for enabling embodiments of the present disclosure, are descriptive of some of the embodiments and are not intended to limit the scope of the disclosure. The figures are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Wherever applicable, the words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

Figure 1 illustrates an exploded view of a crate and support members of the crate assembly, in accordance with an embodiment of the present disclosure.

Figure 2 illustrates an isometric view of a plurality of crates forming a first layer of the crate assembly and the support members. Figure 3 illustrates an isometric view of the crate assembly depicting the first layer of crates of Figure 2 placed on a base pallet.

Figure 4 illustrates an isometric view of the crate assembly depicting articles disposed in the first layer of crates.

Figure 5 illustrates an isometric view of the crate assembly depicting a second layer of crates formed on the first layer of crates.

Figure 6 illustrates an isometric view of the crate assembly depicting articles disposed in the second layer of crates.

Figure 7 illustrates an isometric view of the crate assembly depicting a plurality of layers of crates stacked on each other. Figure 8 illustrates an isometric view of the crate assembly depicting an enclosure.

Figure 9 illustrates an isometric view of the crate assembly depicting a cover.

Figure 10 illustrates an isometric view of the crate assembly depicting a lid and straps. Figure 11 illustrates an exploded view of the crate and support members of the crate assembly, in accordance with another embodiment of the present disclosure.

Figure 12 illustrates an isometric view of the crate of Figure 11 and an article disposed therein.

Figure 13 illustrates an exploded view of the crate and support members of the crate assembly, in accordance with yet another embodiment of the present disclosure.

Figure 14 illustrates an exploded view of the crate and support members of the crate assembly of Figure 13, and a locking and stacking cap.

Figure 15 illustrates an isometric view of the crate and support members of the crate assembly of Figure 13, and the locking and stacking caps mounted on the crate. Figure 16 illustrate an isometric view of the crate of Figure 13 and articles disposed in the crate.

Figure 17 illustrates an isometric view of the crates of Figure 13 placed on the base pallet.

Figure 18 illustrates an isometric view of the crate assembly depicting articles disposed in the first layer of crates of Figure 13. Figure 19 illustrates an isometric view of the crate assembly depicting a plurality of layers of crates of Figure 13 stacked on each other.

Figure 20 illustrates an isometric view of the crate assembly depicting a plurality of layers of crates of Figure 13 stacked on each other and the enclosure.

List of Reference Numerals 100 - Crate assembly

110 - Crate

112 - Beam 113 - Spacer beam

114 - Pockets

120 - Support or load carrying member 130 - Recess

140 - Ribs

145 - Support or load carrying pillar 147 - Interlock on the pillar

150 - Locking and stacking cap 155 - body of the cap

160 - Extensions

165 - Provision

170 - Base pallet

180 - Skirting wall

190 - Enclosure

195 - Cover

200 - Top Lid

205 - Straps

300, 305, 310 - Articles

DESCRIPTION The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the disclosure. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. The terms and words used in the following description are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present disclosure are provided for illustration purpose only and not for the purpose of limiting the disclosure as defined by the appended claims and their equivalents.

Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

The present disclosure envisages a modular crate assembly. The modular crate assembly, of the present disclosure, eliminates the need of a master box. Further, the crate assembly can be configured onsite and the height and width of the crate assembly is adjustable as per the size of articles to be conveyed.

The modular crate assembly (hereinafter also referred to as assembly), of the present disclosure, is now described with reference to Figure 1 through Figure 20. Referring to Figure 1 to Figure 20, various embodiments of a crate assembly 100 are shown.

The assembly 100 comprises a plurality of crates 110 stacked upon each other in a spaced apart configuration. The assembly 100 comprises at least one support or load carrying member 120 removably connected between each of two stacked crates 110. In an embodiment, the assembly comprises a plurality of support members 120 removably connected between each of two stacked crates. The support member 120 is configured to support a crate 110 mounted thereon. More specifically, the crates 110 are arranged vertically upon each other to form a stack. The support members 120 are connected between two stacked crates 110.

In an embodiment, the assembly 100 comprises at least two layers of the crates 110, wherein each layer of the crates 110 has at least one crate 110. At least one support member 120 is removably connected between two layers of the crates 110.

In another embodiment, the assembly 100 comprises an array of crates 110 stacked upon each other. Each layer of the array comprises a plurality of crates 110 arranged abutting each other. More specifically, a side of each crate 110 abuts at least one side of another crate 110. The crates 110 in one layer can be secured to each other by various fastening means to prevent lateral displacement of the crates 110 with respect to each other. In an embodiment, the sides of the crates 110 are provided with interlocking arrangement so that the side can be locked with a side of other crate 110. In an embodiment, the crates 110 in a layer are connected to each other via interlocks. In yet another embodiment, the crates 110 in a layer are connected to each other via fasteners to prevent lateral displacement of said crates with respect to each other.

In an embodiment, each layer of the crate assembly 100 has equal number of the crates 110. In another embodiment, each layer of the crate assembly 100 has varying number of crates. Further, shape and size of the crates 110 in each layer can be same or can vary.

In an embodiment, the crate 110 has a square or rectangular shape. It is to be noted that the geometry/shape of the crate 110 is not limited to square or rectangular, and can be altered as per the article requirement like circle, hexagon, etc.

Further, each of the crates 110 comprises recesses 130 configured on an operative top surface and an operative bottom surface of the crates 110 to receive the support member(s) 120. In case the assembly 100 comprises one support member 120, only one recess 130 is configured on the operative top surface and the operative bottom surface of the crates 110. The recesses 130 have shape and size complementary to the shape and size of the support members 120 received in the recesses 130. Further, locations of the recesses 130 are determined as per the structural load requirement of the assembly 100. In an embodiment, the recesses 130 are configured at operative corners of each crate 110. In another embodiment, one recess 130 is configured at the center of each crate 110, more specifically, on the central portion of the top and bottom surface of the crate 110. In yet another embodiment, the recesses 130 are formed at the corners and at the center of the top and bottom surface of each crate 110. The size, shape and location of the recesses 130 are determined in order to facilitate the fitment of the support member 120. In an embodiment, the number of recesses 130 is not only equal the number of support members 120, and can be equal or less or more than the support members 120. The support member 120 is configured to be removably fitted in the recesses 130. The support member 120 is push fitted or plugged or inserted in respective recess 130. The shape and size of the support member 120 is determined as per load bearing requirement for the support member 120. The support member 120 is sturdy enough to take the load of a plurality of crates 110 stacked thereon and articles disposed in each of the crates 110. Some examples of articles 300, 305, 310 that can be conveyed using the crate assembly 100 are shown the Figures 4, 6, 7,

12, 16, 17, 18, and 19.

In an embodiment, the support member 120 is a structured or rigid bar. A plurality of ribs 140 is configured on an operative outer surface of the support member 120 along the longitudinal axis thereof. The ribs 140 limit downward displacement of the crate 110 stacked upon the support member, and provide structural strength to the support member 120 to bear the load thereon. In an embodiment, the support member 120, i.e., the structured or rigid bar has a taper along the length thereof.

In an embodiment, each of the support members 120 has shape of a frustum.

It should be noted that the geometry, shape, size and structural features of the support members 120 are determined to fulfill the load carrying requirements, and are not limited to ribs or taper configuration. The height of the support members 120 is determined by taking into account the distance required to be maintained between the crates and/or height of the articles to be conveyed.

In another embodiment, the support member is a locking and stacking cap 150. The cap 150 comprises a body 155, and a plurality of extensions 160 extending from the body of the cap 150. The extensions 160 are configured to be received in the recesses 130 configured on each of the crates 110.

The assembly 100 further comprises a base pallet 170. The base pallet 170 forms the base of the assembly 100. The base pallet 170 is configured to support the stack of the crates 110 thereon. The base pallet 170 is further configured to facilitate lifting of the stacked crates 110. Due to the base pallet 170, the assembly can be conveniently lifted using lifting equipment such as a forklift. In an embodiment, the base pallet 170 has a square or rectangular shape.

The assembly 100 further comprises a skirting wall 180 extending upwardly from the periphery of the base pallet 170. In an embodiment, the height of the skirting wall 180 ranges from 50 mm to 100 mm. It should be noted that the height of the skirting wall mentioned hereinabove is for purposes of examples, and is not limited to aforementioned dimensions.

To form the assembly 100, a first layer of the crates 110 is formed on the base pallet 170 by placing a single crate 110 or multiple crates 110 on the base pallet 170. The base pallet 170 can be provided with the skirting wall 180. If not, the skirting wall 180 is provided on the base pallet. The first layer of the crates 110 can have a single crate 110 or a plurality of crates 110 connected to each other. Further, the support members 120 are push fitted in the recesses 130 configured on the top surface of the crates 110. Now articles to be conveyed are disposed in the crates 110. Further, a second layer of crates is formed by mounting another set of crates 110 on the support members 120 push fitted in the crates of the first layer. Articles are then disposed in the crates of the second layer. The procedure of forming layers of the crates, inserting support members in the recesses, disposing articles in the crates, stacking crates on that layer of the crates, disposing articles in the crates is repeated till all the articles are disposed in the crates. The size and shape of the crates 110 are determined as per the application requirement or the size and shape of the articles to be conveyed. In an embodiment, an operative top surface of each of the crates 110 has a shape complementary to the shape of articles to be received in the crates 110. In another embodiment, each of the crates 110 comprises a plurality of beams 112 connected to each other defining a closed profde. Such type of crate is particularly useful in conveying cylindrical articles 310 from one place to another. In an embodiment, the beams 112 are arranged in a parallel configuration. The space between the beams 112 is maintained by a spacer beam 113 connected orthogonally to the parallel beams 112. The beams 113 and the spacer beams 113 are connected using support pillars 145 (also known as load carrying pillars). Interlocks 147 are configured on the support pillars 145 to facilitate connection of the parallel beams 112 and spacer beams 113 with the support pillars 145 or the male interlocks can even be a separate child feature which can be inserted later between the recesses provided for assembly of beam and pillar and these interlocks can be further used to lock the adjacent crates used in plurality to make a large assembled crate. In some case Pillar and Beam can be a integral part having female recess or features to accommodate the male interlocks later. Further, the support pillars 145 are provided with provisions 165, typically in the form of holes, to receive the extensions 160 of the locking and stacking cap 150.

Impressions and/or pockets are configured on each of the crates 110 which have the shape and size complementary to the articles to be conveyed. The arrangement of impressions/pockets restricts the movement of the articles during transportation and ensures reception of the articles in proper orientation in the crate. In an embodiment, each of the crates 110 comprises a plurality of pockets 114 formed on the operative top surface of the crate 110. The pockets 114 have a shape complementary to articles received in the crate 110. In an embodiment, the pockets 114 have a shape complementary to the articles 300, 305, 310. The assembly 100 comprises an enclosure 190 configured to cover the stacked crates 110. In an embodiment, the enclosure 190 is a volatile corrosion inhibitor (VCI) bag. The assembly further comprises a cover 195 mounted on the topmost layer of the stacked crates 110. In an embodiment, the cover 195 is of polypropylene corrugated sheet which is die-cut to form the cover 195. Holes are configured on the cover 195 to receive the support members 120 mounted on the topmost layer of crates 110. It should be noted that the material of the cover 195 is not limited to polypropylene. The cover 195 can be of vacuum or thermoformed trays or any other material/ method option which fulfills the application requirement of top stopper and support.

The assembly further comprises a top lid 200 mounted on the enclosure 190. The lid 200 has a skirting wall extending downwards. The base pallet 170, the stack of crates 110, the lid 200, and the enclosure 190 are strapped together using straps 205.

The base pallet 170 and the lid 200 are made of wood, plastic or steel as per the application usage, delivery destination, reusability, recyclability, and cost.

The crates 110 and the support members 120 can be made of any suitable material. In an embodiment, the crates 110 are made of reprocessed polymers which are good for environment and are cost effective too. Thus, the packaging cost of the assembly 100 is reduced drastically. Reprocessed crates, if needed, can be used one time and handed over to recycler who can grind the crates into small pieces and further reprocess it to make tiny pellets or granules which are ready again for molding new crates. It should be noted that the scope of the material of the crate 110 is not limited to reprocessed polymer. The material of the crates 110 is selected on basis of higher strengths and life cycles requirement. In an embodiment, the crate 110 can be of virgin polymers or any other suitable material which fulfills the application or strength requirement.

The assembly 100 is modular, sturdy, strong, less expensive, and is recyclable. The crate assembly, of the present disclosure, eliminates the need of a master box and internal partitions used in the conventional packaging arrangement. Such components pose a hazard to the environment, and are disposed into the environment only after one time use in most of the cases. The crate assembly is durable enough to take multiple vertical stacking loads of additional similar units, and can be used multiple times to convey articles. Further, the assembly 100 is modular in nature, and can be assembled onsite or can be transported in assembled state at a location.

Further, a user does not require continuous leaning downwards to place articles in the crates 110. The user forms a layer of crates, and places articles in them. A new layer of crates is formed as per the requirement. Thus, the assembly 100 is ergonomical in nature. Use of the assembly 100 improves the working effectiveness and thereby efficiency of a user.

TECHNICAL ADVANCEMENTS

The crate assembly of the present disclosure:

• eliminates the need of a master box;

• improves work ergonomics by reducing human back pain and arm stretching fatigue caused due to bending through side walls of a conventional master box while placing and picking articles;

• is modular;

• is ergonomical;

• ensures safe and easy packaging of articles; and

• is environment friendly as reduces use of Wood or corrugated paper in packaging

• improve supply chain effectiveness and reduce overall cost

Claims

CLAIM

1. A modular crate assembly, said assembly comprising: a plurality of crates stacked upon each other in a spaced apart configuration; and at least one support member removably connected between each of two stacked crates, and configured to support a crate mounted thereon.

2. The assembly as claimed in claim 1, which comprises a plurality of support members removably connected between each of two stacked crates.

3. The assembly as claimed in claim 2, wherein each of said crates comprises recesses configured on an operative top surface and an operative bottom surface of said crates to receive said support members.

4. The assembly as claimed in claim 1, wherein said support member is a locking and stacking cap comprising a body, and a plurality of extensions extending from said body.

5. The assembly as claimed in claim 1, wherein said assembly comprises a base pallet configured to support said stacked crates thereon, and said base pallet further configured to facilitate lifting of said stacked crate.

6. The assembly as claimed in claim 5, wherein said assembly comprises a skirting wall extending upwardly from the periphery of said base pallet.

7. The assembly as claimed in claim 1, wherein said assembly comprises an array of crates stacked upon each other, and each layer of said array comprises a plurality of crates arranged abutting each other.

8. The assembly as claimed in claim 7, wherein the crates in a layer are connected to each other via interlocks to prevent lateral displacement of said crates with respect to each other.

9. The assembly as claimed in claim 7, wherein the crates in a layer are connected to each other via fasteners to prevent lateral displacement of said crates with respect to each other.

10. The assembly as claimed in claim 1, wherein said assembly comprises an enclosure configured to cover said stacked crates.

11. The assembly as claimed in claim 1, wherein said assembly comprises a cover mounted on the topmost layer of said stacked crates.

12. The assembly as claimed in claim 1, wherein an operative top surface of each of said crates has a shape complementary to the shape of articles to be received in said crates.

13. The assembly as claimed in claim 1, wherein each of said crates comprises a plurality of beams connected to each other defining a closed profile.

14. The assembly as claimed in claim 1, wherein each of said crates comprises a plurality of pockets formed on an operative top surface of said crate, and each of said pockets has a shape complementary to articles received in said crate.