AU2008243234A1 - A roll support assembly - Google Patents

Description

Regulation 3.2 AUSTRALIA PATENTS A CT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT ORIGINAL Name of Applicant CARTER HOLT HARVEY I.IMITED Actual Inventor: BONNER, Craig Ronald Address for service in Australia: A J Park, Level 11, 60 Marcus Clarke Street, Canberra, ACT 2601 Invention Title: A Roll Support Assembly Details of Associated Provisional Application: NZ568244 filed 12 May 2008 NZ5 69457 filed 26 June 2008 NZ569973 filed 21 July 2008 The following statement is a rull desanption of this invention, including the best method of performing it known to mc/us -2 Technical Field The present invention relates to apparatus, methods and procedures useful in the transportation and/or storage of rolls. 5 Background Art Heavy rolls, typified by coreless coils ("rolls") of sheet metal or cored paper rolls ("rolls') frequently require stabilisation during storage and/or transportation. In the case of sheet metal rolls, these are coreless, exceptionally heavy and have surfaces not to be damaged. To avoid roll to roll contact, which can be damaging, such rolls 10 are usually individually supported away from other such rolls. In a shipping container, owing to the great weight of such rolls, it is usual to provide rolls in alignment with the longitudinal axis of the shipping container so that the rolls can be extracted by insertion of a lifting protuberance (eg, a fork of a forklift) directly into the hollow centre of the roll. Cradling of such rolls in that condition, with or without dunnage, is used to 15 avoid movement that is detrimental to the roll, its alignment for removal, and/or the wellbeing of the container. The present invention recognises an advantage in providing, and has as one object the provision of, a cradle support for such rolls whether, for standing storage but preferably for use in such shipping containers, which is almost exclusively (save for adhesives, eg, PVA 20 or others) of paper or paperboard material, or at least reduces the need for less recyclable or less "green" alternatives. Such apparatus, systems and methodology has a further or alternative aim the avoidance of polystyrene usage. As used herein "roll" in respect of the cradled or to be cradled entity can be cored or uncored ie, it can be a coil of sheet material. 25 As used herein the term "paper" and the term "paperboard" are to be considered interchangeable, ie, they are essentially a web or a plurality of webs (some corrugated or not) of cellulosic fibres. As used herein the term "corrugated board" envisages paper or paperboard sheet lined laminates of fluted paper or paperboard. There can be commonality of flute run or 30 disparate flute runs. Interposed sheet linings can be provided between such flute runs. As used herein the term "and/or" means "and" or "or", or both. As used herein the term "(s)" following a noun includes, as might be appropriate, the singular or plural forms of that noun.

As used herein "flank" or "fankingq" with respect to the cradle member mcans, if it has the preferred curved zone, on either underside of the convex curve. Likewise for any outstand or flange from the ends of the curved zone ie, the side regions underneath. In other context, the term "flank" or "flanking" can be with respect of the 5 relationships the cradle member has to the roll or coil to be supported ie, the outstands or flanges flank and are supported by cach flanking support of the cradle member. Disclosure of Invention In an aspect the invention is roll or coil cradle apparatus ("roll cradle apparatus") 10 supporting in a freight container, or suitable for use in at least a freight container to support, a roll or coil ("roll"), said apparatus comprising or including a cradle member having the roll, or adapted to have the roll, at least in part supported and cradled by lying thereon or there across, or both, and a pair of similar or dissimilar supports for the cradle member, each support (eg, as if a 15 rib support) in part underlying and supporting, or being adapted in use to underlie and to support, in part, the cradle member from a different side with respect to a roll being cradled, or to be cradled. Preferably said cradle member is a paperboard laminate. Preferably said paperboard laminate includes flute run plies. 20 Preferably said cradle member includes a curved zone on which the toll is supported or is to be supported (ie, by the underlying rib support), and outstands or flanges at each end of said curved zone. Preferably one or both of said supports for the cradle member includes two or more complementary self supporting paperboard laminate members. 25 Preferably the two, or the outer two, complementary self supporting paperboard laminate members, each at least in part underlie, or is adapted to underlie, a flank of part of a curved zone, or the curved zone, of the cradle member. Preferably the two, or the outer two complementary self supporting paperboard laminate members, each at least in part underlies, or is adapted to underlie, an outstand or 30 flange from said curved zone. Preferably cach said support is of at least two complementary members each receiving one or more spanning members) through an opening or openings to support the mutual spaced relationship of the complementary members. Preferably the or each said opening of a said complementary member receives, or is 35 adapted to receive, a tube, paper roll or paper tube.

-4 Preferably the, or each, said tube, paper roll or paper tube is a helically wound paper. The apparatus preferably is substantially as herein disclosed with or without reference to any one or more of the accompanying drawings. The invention also is, in combination, components of roll cradle apparatus previously 5 defined. The invention also is, in disassembly or partial assembly, or total assembly, apparatus as previously defined. In still another aspect the invention is a cradle member of or suitable for roll cradle apparatus as previously defined, said cradle member being at least primarily of paper or 10 paperboard. Preferably the cradle member is substantially as herein described with reference to any one or more of the accompanying drawings. In yet another aspect the invention is a component of, for, or suitable for, apparatus as previously defined, being a said complementary member, formed from a paper or paperboard 15 sheet or laminate of, for, or suitable for roll cradle apparatus as previously defined. Preferably it has a plurality of openings therethrough. Preferably it includes at least a scalloped edge to at least partially underlie and support part of a said cradle member. Preferably that has edge to underlie at least part of an outstand or flange of a said 20 cradle member. Preferably the complementary member is substantially as herein described with reference to any one or more of the accompanying drawings. In another aspect the invention is a method of transportation of a roll or for stabilising a roll, which involves the use of at least two roll cradle apparatus as previously defined to 25 support a roll lying on or across each of the cradle members. Preferably said roll is a steel, metal or other heavy roll or coil. Preferably the method is performed substantially as herein described with or without reference to any one or more of the accompanying drawings. In another aspect the invention is a shipping container containing roll cradle apparatus 30 as previously defined and a roll or coil supported by such apparatus. Preferably there are at least a spaced pair of said roll cradle apparatus. Preferably a dunnage member is interposed between said roll cradle apparatus and/or between said rolls and/or between a, or each, said roll cradle apparatus and/or roll and a wail of the container.

-5 In another aspect the invention is a lie flat dunnage assembly comprising, when in its undeployed condition, one panel lying against another panel to which it is hinged but which, when deployed to its dunnage condition, has the proximal edge of one panel against the face of the other panel. 5 Preferably each said panel is rectangular or square. Preferably each said panel is the same or of a different size but of the same length in the direction parallel to the hinging axis. Preferably hinging is provided by a strip adhered to the face of each paneL Preferably each panel is a lamination of paperboard. 10 The invention is also the use of a lie flat dunnage assembly as defined. Preferably said use is to separate metal coils or rolls, each held in a shipping container on one or more roll cradle apparatus as defined. The invention also is a containetisation solution or system of heavy roll or coil transportation substantially as herein described, 15 In still a further aspect, the invention consists in a cradle member, being a paperboard laminate (preferably including plural flute run plies throughout the laminate) which defines a cradling curve that is substantially self supporting. Preferably said cradling curve is of uniform cross-section. Preferably said cradling curve includes outstands or flanges outwardly from the top 20 thereof of its cradling curve. Preferably said curve is adapted to cater for a specific roll or range of specific roll szes. In a further aspect the invention consists in a support assembly for supporting one side of such a cradle member as aforesaid, said support assembly comprising or 25 including at least two complementary self supporting paperboard members, each able to have a profile of and/or at an edge underlie part of the exterior of a said cradling curve from below, and at least one member to hold said complementary members substantially mutually parallel, but apart, so that each can support the same cradle member. The said complementary members are each of a paperboard laminate, preferably with 30 multiple plies of both sheet paper/paperboard and fluted paper/paperboard. Preferably at least the majority of the flute run direction will be upwardly when such complementary members support a cradle member in use. Preferably said complementary members each has an edge to touch the underlying exterior of the cradling curve of the cradle member as well as a non curved edge to underlie an 35 outstand or flange that extends outwardly from the top of said cradling curve.

-6 Preferably each of said two complementary members includes openings adapted to receive a plurality of said members to hold said complementary members substantially mutually parallel, but apart. Preferably said openings are adapted to receive elongate rolls of a paper material, eg, 5 helically wound rolls. Preferably said rolls are a tight fit through such openings so as to provide stability against movement. Such a tight fit however is not essential. Preferably there are at least three rolls for tying together each pair of complementary members. 10 In some forms there can be three or more complementary members for each support assembly, ic, one assembly to either side of a single cradle member. In a further aspect the invention consists in a support assembly or a pair of complementary support assemblies as previously defined together with a supportable or supported cradle member, 15 Tn another aspect the invention is a cradling system for rolls, said system requiring the use, in a shipping container, of cradle defining subassemblies and/or laminates at least primarily of paper or paperboard on which the rolls are to be or are placed. Preferably each cradle for a roll comprises at least two assemblies, each of a cradle profile laminate, and two profiled supports to support such laminate from under both sides of 20 notional "roll axis" of the cradle profile laminate. The invention in another aspect consists in a roll support assembly and/or combination, comprising or including at least two cradle members, and, for each cradle member, a pair of flanking support assemblies, each to at least in part 25 underlie the cradle member; wherein said cradle members, when each supported by a said pair of flanking support assemblies, can act together to cradle a roll (for example, a roll of sheet metal); and wherein one or both of (a) the at least two cradle members and/or (b) the each pair of flanking support assemblies is primarily formed from paper and/or pulp. 30 Preferably each said cradle member is a laminate of corrugated board, ie, both corrugated plies of paper or paperboard with a flute run) and non corrugated paper or (eg, without a paperboard flute run). Preferably said flanking support assemblies are each a fabrication involving a spacing member or spacing members (preferably of paperboard and/or pulp construction). For 35 example, helically wound rolls of paper or paperboard, spacing and supporting through -7 openings at least two laminates of paperboard, eg, preferably of a mix of both flute run and non flute run paper webs. Preferably the arrangement is substantially as hereinafter described. In a further aspect the invention consists in, in a "shipping container' a roll 5 support assembly and/or combination as previously defined operatively supporting a roll in the at least two cradle members. Preferably said cradle members are in alignment within said container. Preferably said flanking support assemblies fit with little or no dunnage between sides of the shipping container such that the roll extends longitudinally of the container 10 length. In other forms of the present invention, dunnage can be provided to confer some spacing support between pairs of flanking support assemblies and their cradle member. In a further aspect the invention consists in a cradle member at least primarily of paper or paperboard suitable for use as aforesaid. 15 In a further aspect the invention consists in a flanking and/or underlying support assembly suitable for use as previously described. In preferred forms of the present invention there is a said pair of flanking support assemblies. In less preferred forms of the present invention there can be a unitary assembly 20 which in conjunction with the cradle members, provides the desired outcome, ie, serves an equivalent function to such a pair of flanking support assemblies. In preferred forms of the present invention said cradle members are not adhesively affixed to said pair of flanking support assemblies but can well be so. Preferably each said cradle member is self supporting. 25 Preferably said cradle member includes an outer flange at the top of the curvature of its preferred laminate structure, the lamination axes being aligned to be parallel to the roll axis to be supported thereby etc. In another aspect the invention is, as a containerisation solution or a system of heavy rol transportation, a use of a system, method, and/or assemblies as herein described, 30 the provision of one or more components as herein described, or as herein described with reference to any one or more of the accompanying drawings, and/or at least one dunnage assembly substantially as herein defined or substantially as herein described with reference to the accompanying drawings. In another aspect the invention is a lieflat dunnage assembly comprising, when in 35 its undeployed condition, one panel lying against another panel to which it is hinged but -8 which, when deployed to its dunnage condition, has the proximal edge of one panel against a face of the other panel. Preferable each panel is rectangular or square. They can be the same or different sizes but are preferably the same length in the direction parallel to the hinging axis. 5 Preferably hinging is provided by a strip adhered to the face of each panel. Preferably each panel is a lamination of paperboard (eg, multiple layers of corrugated board). Preferably the assembly is as shown. The invention also consists in the use of such a lieflat dunnage assembly. 10 Preferably the use is to separate metal coils each held in a shipping container on a cradle assembly or array thereof. In any of the aforementioned embodiments, in order to accommodate different coil sizes, the matching to a range of coil sizes and coil weights can be such as to allow, for larger coil diameter and weight, some crushing of the flanking supports as the cradle member is 15 forced outwardly. See for example Figure 8 hereafter. Brief Description of Drawings A preferred form of the present invention will now be described with reference to the accompany drawings in which 20 Figure 1 is a perspective view of a preferred cradling arrangement in accordance with the present invention, Figure 2 is a view of a preferred cradling member in accordance with the present invention, preferably formed from multiple ply corrugated board and preferably formed as one piece or alternatively, as shown, fabricated to provide the outstands or flanges at each 25 upper extremity ie, from the end of the curved region, Figure 3 is a preferred assembly to support each flank at least partly from below of a component as shown in Figure 2, Figure 4 is another view of the component of Figure 3, Figure 5 is an alternative arrangement to that of Figures 3 and 4, ie, a less preferred 30 embodiment, Figure 6 shows a similar view to that of Figure 1 but using the flanking or supporting assemblies of Figure 5 rather than that of Figures 3 and 4, Figure 7 is a view in use (preferably as it would be in a shipping container), of multiple metal rolls in alignment, each supported by at least one dunnage stabilised -9 arrangement of the present invention, the arrangement showing a mixture of the components on the one hand of Figures 3 and 4 and on the other hand of Figure 5, Figure 8 shows a diagram of how different coil sizes can be accommodated with or without crushing of the cradle member into the flanking supports, 5 Figure 9 is a perspective view of a preferred blank for assembly with the rolls into a rib assembly to flank one side of the cradle member, Figure 10A is a perspective view of the rib assembly, Figure 10B is a plan view of the rib assembly of Figure 1 OA, Figure 1OC is a perspective view of such a rib assembly underlying part of a cradle 10 member, Figure 11 is a preferred cradle member as depicted in Figure 10C, the member being shown in isometric, Figure 12 is a simplified assembly drawing of two rib assemblies and the cradle member described earlier with reference to Figures 9 to 12, 15 Figure 13 shows two such cradle assemblies mounted in a shipping container and adapted to contain a range of different size rolls, Figure 14 shows the arrangement as in Figure 13 bearing the weight of two metal coil rolls, Figure 15 shows a dunnage assembly in accordance with the present invention 20 bearing against one end of a roll as it would be as a dunnage unit interposed between rolls as in Figure 14, behind the furthermost roll as in Figure 14 and in front of the roll foremost roll in Figure 14, Figure 16A shows the deployed dunnage item, Figure 16B shows the item of Figure 16A also in perspective but from the other end 25 when deployed, (NB normally used with hinged apex topmost), and Figure 17 shows from below one end of a used cradle member in accordance with the present invention showing the outcome of the mutual crushing that will occur between the ribs and the cradle member to allow the settling down of a roll within an appropriate range of roll sizes as discussed with respect to Figure 8. 30 In the preferred form of the present invention there is provided a cradling or cradle member I with its general shape adapted to nest with low loading (cradle to roll) a roll as shown in Figure 7. Each cradle member 1 has its curved region 2, the lower extremity of which 3 is to rest on or just above a support surface, and the outreaching flanges 4 unitarilyy formed with the region 2 in preference to a fabrication process) being supported from 35 beneath by part of an assembly 5 as described in more detail with reference to Figures 3 and 4.

-10 The assembly 5 comprises spaced but mutually parallel profited members 6 with a profiled edge 7 to position against the outside of the member 1. There is also an upper edge 8 which is to underlie flanges 4 to stabilise and locate the cradle member 1. The mutual spacing of the members 6 is preferably provided by a plurality of helically 5 or other formed paper rolls 9 placed tightly through openings of each member 6 so as to provide the stability in the arrangement as shown in Figure 1 Shown in Figure 7 is a hybrid mix of the structure as shown in Figures 1 through 4 and the alternative arrangement of Figures 5 and 6. In Figures 5 and 6 there is a fabricated adhesively attached pair of supporting sheets 10 and 11. See how in Figure 6 they are used 10 instead of the arrangement of Figures 1, 3 and 4. Persons skilled in the art will appreciate how, if desired, a longer roll than any of those shown in Figure 7 can be cradled between aligned pairings or groupings of the arrangements shown. It is envisaged that the material will be a laminate of 5 times horticultural grade 15 POWER PLYTM corrugated board. The lamination is with a suitable adhesive, (eg, PVA or other). The form of the curved cradle member is provided by placing over a jig and lower forming the roll to set the curve. The side supports 4 of a similar material can be die cut and laminated and held in place. In some preferred forms of the present invention the supports 4 can be formed integrally (and this is preferred) with the general curved region. 20 It is envisaged that a similar material to that of the component I will be used for each of the planar members 6, each will preferably be die cut to have the profiles required and the openings into which cut to length standard helically wound paperboard roll members can be inserted. Figure 8 shows how a cradle member of, say, 1255 mrnm diameter curve can be fitted 25 to, say, a 662.5 mm radiused flanking member, yet with or without crushing by the coil, and thus parts of the cradle member, into the flank support, can accommodate coils of, say, from about 1255mm diameter to at least about 1655 nu diameter. By way of example, such measurements using, say, 35 mm thick cradle members linked as previously described can accommodate at least three coil sizes, the largest being preferably limited to intrude with 30 crushing preferably no further than the top roll in the flanking member as shown in Figure 8. A preferred range of blank components and sub-assemblies shown in Figures 13 through 17. Figure 9 shows a preferred form of rib forming blank 10 with its three openings, each provided with some small amount of star bursting at 11.

- I I Such a blank is of a laminate similar to that that which might be used for the cradle member 12. The assembly can be seen from the drawings from which it can be seen that there are three blanks 10 used in each assembly of three ribs 10 in conjunction with three rolls 13. 5 These are interference fitted but may be glued. Figure 15 shows a dunnage item 14 of the same or different laminate. It involves a hinge strip 17 adhered to a face of each of panels 15 and 16 in such a way the edge of panel 16, when deployed, beats on a face of panel 15. The dunnage item preferably sits against each roll as a spacer, the roll axes being 10 parallel to the strip 17 provided hinge axes. Figure 17 at 18 shows regions of crushed laminate arising from the mutual settling together of ribs 10 and the cradle 12 under roll weight In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of 15 providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.

Claims (34)

1. Roll or coil cradle apparatus ("roll cradle apparatus") supporting in a freight container, or suitable for use in at least a freight container to support, a roll or coil ("roll"), said apparatus comprising or including 5 a cradle member having the roll, or adapted to have the roll, at least in part supported and cradled by lying thereon or there across, or both, and a pair of similar or dissimnilar supports for the cradle member, each support in part underlying and supporting, or being adapted in use to underlie and to support, in part, the cradle member from a different side with respect to a roll being cradled, or to be cradled. 10

2. Apparatus as claimed in claim 1 wherein said cradle member is a paperboard laminate.

3. Apparatus of claim 2 wherein said paperboard laminate includes flute run plies.

4. Apparatus as claimed in any one of the preceding claims wherein said cradle member includes a curved zone on which the roll is supported or is to be supported, and outstands or flanges at each end of said curved zone. 15

5. Apparatus as claimed in any one of the preceding claims wherein one or both of said supports for the cradle member includes two or more complementary self supporting paperboard laminate members.

6. Apparatus of claim 5 wherein the two, or the outer two, complementary self supporting paperboard laminate members, each at least in part underlie, or is adapted to 20 underlie, a flank of part of a curved zone, or the curved zone, of the cradle member.

7. Apparatus of claim 6 wherein the two, or the outer two complementary self supporting paperboard laminate members, each at least in part underlies, or is adapted to undedie, an outstand or flange from said curved zone.

8. Apparatus as claimed in any one of the preceding claims wherein each said support is 25 of at least two complementary members each receiving one or more spanning members) through an opening or openings to support the mutual spaced relationship of the complementary members.

9- Apparatus of claim 8 where the or each said opening of a said complementary member receives, or is adapted to receive, a tube, paper roll or paper tube. 30

10. Apparatus as claimed in claim 9 wherein the, or each, said tube, paper roll or paper tube is a helically wound paper.

11. Apparatus as claimed in any one of the preceding claims substantially as herein disclosed with or without reference to any one or more of the accompanying drawings.

12. In combination, components of roll cradle apparatus as claimed in any one of the 35 preceding claims.

- 13 13. In disassembly or partial assembly, or total assembly, apparatus as claimed in any one of claims 1 to 11.

14. A cradle member of or suitable for roll cradle apparatus as claimed in any one of claims to 11, said cradle member being at least primarily of paper or paperboard. S

15. A cradle member as claimed in claim 14 substantially as hereinbefore described with reference to any one or more of the accompanying drawings.

16. A component of, for, or suitable for, apparatus of any one of claims I to 11, being a said complementary member, formed from a paper or paperboard sheet or laminate of, for, or suitable for roll cradle apparatus as claimed in any one of claims 1 to 11. 10

17. A component of claim 16 having a plurality of openings therethrough.

18. A component of claim 16 or 17 wherein it includes at least a scalloped edge to at least partially underlie and support part of a said cradle member.

19. A component of claim 18 that has edge to underlie at least part of an outstand or flange of a said cradle member. 15

20. A complementary member as claimed in any one of claims 16 to 19 substantially as hereinbefore described with reference to any one or more of the accompanying drawings.

21. A merbod of transportation of a roll or for stabilising a roll, which involves the use of at least two roll cradle apparatus as claimed in any one of claims I to 11 to support a roll lying on or across each of the cradle members. 20

22. A method as claimed in claim 18 wherein said roll is a steel, metal or other heavy roll or coil.

23. A method as claimed in claim 21 or 22 when performed substantially as hereinbefore described with or without reference to any one or more of the accompanying drawings.

24. A shipping container containing roll cradle apparatus as claimed in any one of claims 25 1 to 11 and a roll or coil supported by such apparatus.

25. A shipping container wherein there are at least a spaced pair of said roll cradle apparatus.

26. A shipping container as claimed in claim 25 wherein a dunnage member is interposed between said roll cradle apparatLs and/or between a, or each, said rol cradle apparatus and a 30 wall of the container.

27. A lie flat dunnage assembly comprising, when in its undeployed condition, one panel lying against another panel to which it is hinged but which, when deployed to its dunnage condition, has the proximal edge of one panel against the face of the other panel.

28. Assembly as claimed in claim 27 wherein each said panel is rectangular or square. -14

29. An assembly as claimed in claim 27 or 29 wherein each said panel is the same or of a different size but of the same length in the direction parallel to the hinging axis.

30. An assembly as claimed in any one of claims 27 to 30 wherein hinging is provided by a strip adhered to the face of each panel. 5

31. An assembly as claimed in any one of claims 27 to 30 wherein each panel is a lamination of paperboard.

32. The use of a lie flat dunnage assembly as claimed in any one of claims 27 to 31.

33. The use of a lie flat dunnage assembly of any one of claims 27 to 31 to separate metal coils or rolls, each held in a shipping container on one or more roll cradle apparatus as claimed 10 in any one of claims 1 to 11.

34. A containerisation solution or system of heavy roll or coil transportation substantially as herein described.