US20020017500A1

US20020017500A1 - Frame support and stacking system

Info

Publication number: US20020017500A1
Application number: US09/818,639
Authority: US
Inventors: Terrance Warren
Original assignee: Belmar Corp
Current assignee: Belmar Corp
Priority date: 2000-03-28
Filing date: 2001-03-28
Publication date: 2002-02-14
Also published as: CA2342443A1

Abstract

A system for stacking vehicle frames on a floor support has a floor support with a plurality of upwardly reaching support pillars for holding a bottom frame of a stack of frames, stacking means with a resilient body and a support pin inserted into holes at an end of the frames so that the stacking means separate one of the frames from another of the frames in the stack of frames a predetermined distance. The stacking means has a non-metallic body with an upper end, forming an upper surface, which is angled to cooperate with a lower surface of a the frames, and a lower end, forming a lower surface, which is angled to cooperate with an upper surface of a the frames, and a support rod coated with a plastic material and centrally arranged in the body in a longitudinal direction of the body, the support rod being inserted into holes of the frames.

Description

REFERENCE TO RELATED APPLICATION This is a formal application based on provisional application No. 60/192,563, filed Mar. 28, 2000.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a frame support and stacking system, for securely spacing and holding vehicle frames, or similar, during shipping and storage. Preferably, support means are in the shape of pins, which cooperate with holes on the frames to supportingly hold the frames in relation to each other and a floor support.

2. Description of the Prior Art

Traditionally, frames are stacked one on top of the other on a wooden support (pallet) using all-metal spacers having an elongated pin held in a body. The bottom frame of a stack rests on wooden blocks on the pallet and further frames are stacked on top of the bottom frame using spacers between each pair of frames. Normally, seven frames will form one stack, for transport in a container. The frames are normally strapped to the pallet, using suitable straps. Once placed in a container, the pallet is blocked from movement on the container floor using known techniques. A top surface of the body has a frame resting surface and a hole to receive the lower part of a pin of a spacer of an adjacent frame stacked above, that pin thus protruding out from the bottom of the adjacent frame. The pins of the spacers are inserted into holes in a frame. Spacers of this type has the apparent disadvantage that they easily scratch the frame surface during transport, due to vibrations and movement induced during travel of the transport vehicle (container carrier). The metal construction also makes the spacers sensitive to corrosion, which will weaken the spacer in the long run, possibly to the point where the spacer will break during use.

SUMMARY OF THE INVENTION

It is an object of the invention to provide frame support means for the secure stacking of frames whilst preventing any scratching of the frame surfaces during transportation.

In the invention, a system for stacking vehicle frames on a floor support comprises

a metal floor support, having a plurality of upwardly reaching support pillars for resting a bottom frame of the frames to form a stack of frames,

stacking means, having a resilient body and a support pin inserted into holes at an end of the frames so that the stacking means separate one of the frames from another of the frames in the stack of frames a predetermined distance.

The stacking means preferably comprises a non-metallic body with an upper end, forming an upper surface, which is angled to cooperate with a lower surface of a the frames, and a lower end, forming a lower surface, which is angled to cooperate with an upper surface of a the frames, and a plastic coated support rod centrally arranged in the body in a longitudinal direction of the body, the support rod being inserted into holes of the frames.

The body is advantageously made from plastic, for instance a polyurethane elastomer such as a poly-ether. The coating on the support pin is preferably of the same material as the body.

The stacking means advantageously comprise:

first stacking means, having a first resilient body and a first support pin inserted into holes at a first end of the frames so that the first stacking means separate one of the frames from another of the frames in the stack of frames a first predetermined distance, and

second stacking means, having a second resilient body and a second support pin inserted into holes at a second end of the frames so that the second stacking means separate one of the frames from another of the frames in the stack of frames a second predetermined distance.

The system further advantageously comprises a third stacking means, having a third resilient body and a third support rod inserted into holes on top of a top frame of the stack of frames for providing a resting surface for a strap, or similar.

Preferably, the system further comprises a fourth stacking means, arranged on the support pillars and having a resilient body for providing a resilient support for the bottom frame of the stack of frames.

Advantageously, the system further comprises vertical straps arranged in a general middle portion of the frame stack. The vertical straps preferably has first and second middle straps tied to the floor support and looped over a respective second frame of each the frame stack. The vertical straps may further comprise third and fourth middle straps tying one side of each the frame stack together by looping directly over one frame rail of one the frame stack.

Advantageously, the system further comprises diagonal end straps for each the frame stack, the diagonal end straps looping over top and bottom frames of one the frame stack only without being attached to the floor support.

The system may also advantageously comprise vertical end straps forming a looped end attached around a strut attached to the floor support.

Preferably, the system further comprises longitudinal diagonal straps, looped over a cross-brace of the floor support at a first end of the diagonal straps, the cross-brace running transversely to a longitudinal direction of the floor support, an opposite end of the diagonal straps being looped over an end cross-bar attached to each end of each the frame.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more clearly understood, the preferred embodiment thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which: [0020]
FIG. 1 is a schematic side view of a plurality of stacked frames having support means according to the invention, [0021]
FIG. 1A is a schematic side view of a plurality of stacked frames having support means according to the invention, showing two meshed frame stacks on a common floor support, [0022]
FIG. 2 is a schematic sectional end view along line A-A of FIG. 1, [0023]
FIG. 2A is a schematic sectional end view along line B-B of FIG. 1A, showing two meshed frame stacks on a common floor support, [0024]
FIG. 3 is a schematic elevational perspective side view of a corner of a frame stack having support means according to the invention, [0025]
FIG. 4 is a schematic partially sectioned side view of a part of a frame stack having support means according to the invention, [0026]
FIG. 5 is a schematic partially sectioned end view of a part of a frame stack having support means according to the invention, [0027]
FIG. 6 is a schematic elevational perspective view of a first stacking means according to the invention, [0028]
FIG. 7 is a schematic elevational perspective view of a support rod according to the invention, [0029]
FIG. 8 is a schematic side view of the frame stacking means of FIG. 6, [0030]
FIG. 9 is a schematic end view of the frame stacking means of FIG. 8, [0031]
FIG. 10 is a schematic bottom view of the frame stacking means of FIG. 8, [0032]
FIG. 11 is a schematic top view of the frame stacking means of FIG. 8, [0033]
FIG. 12 is a schematic sectional view of the frame stacking means of FIG. 8, [0034]
FIG. 13 is a schematic sectional view of the frame stacking means of FIG. 9, [0035]
FIG. 14 is a schematic side view of a second stacking means according to the invention, [0036]
FIG. 15 is a schematic end view of the frame stacking means of FIG. 14, [0037]
FIG. 16 is a schematic bottom view of the frame stacking means of FIG. 14, [0038]
FIG. 17 is a schematic top view of the frame stacking means of FIG. 14, [0039]
FIG. 18 is a schematic sectional view of the frame stacking means of FIG. 14, [0040]
FIG. 19 is a schematic sectional view of the frame stacking means of FIG. 15, [0041]
FIG. 20 is a schematic side view of a third stacking means according to the invention, [0042]
FIG. 21 is a schematic end view of the frame stacking means of FIG. 20, [0043]
FIG. 22 is a schematic bottom view of the frame stacking means of FIG. 20, [0044]
FIG. 23 is a schematic partially sectional view of a fourth stacking means according to the invention, showing part of a frame, part of a first/second stacking means and part of a pillar, [0045]
FIG. 24 is a schematic top view of the fourth stacking means according to the invention, showing part of the pillar, [0046]
FIG. 25 is a schematic side view of the stacking means of FIG. 24, [0047]
FIG. 26 is a schematic end view of the stacking means of FIG. 24, [0048]
FIG. 27 is a schematic sectional side view of the stacking means of FIG. 24, [0049]
FIG. 28 is a schematic sectional end view of the stacking means of FIG. 24, [0050]
FIG. 29 is a schematic side view of a stackable floor support according to the invention, having removable pillars in their inserted position, [0051]
FIG. 30 is a schematic side view of a stackable floor support according to the invention, prepared for stacking of further floor supports on top, [0052]
FIG. 31 is a schematic end view of the stackable floor support of FIG. 29, [0053]
FIG. 32 is a schematic end view of the stackable floor support of FIG. 30, [0054]
FIG. 33 is a schematic side view of eight stackable floor supports forming a floor support return shipping stack, [0055]
FIG. 34 is a schematic detail view of stackable floor supports, showing the alignment of floor support stacking pillars before a floor support is stacked on top of another floor support, [0056]
FIG. 35 is a schematic detail view of the stackable floor support of FIG. 34, showing the alignment of floor support stacking pillars after a floor support is stacked on top of another floor support, [0057]
FIG. 36 is a schematic end view of the floor support return shipping stack of FIG. 33, [0058]
FIG. 37 is a schematic end view of FIG. 34, [0059]
FIG. 38 is a schematic end view of FIG. 35, [0060]
FIG. 39 is a schematic side view of a plurality of stacked frames having support means according to the invention, showing two meshed frame stacks on a common floor support and the vertical straps used to secure the frames during transport, [0061]
FIG. 40 is a schematic sectional end view along line [0062] 40-40 of FIG. 39, showing two meshed frame stacks on a common floor support and the vertical straps used in the middle of the frame stacks,
FIG. 41 is a schematic sectional end view along line [0063] 41-41 of FIG. 39, showing two meshed frame stacks on a common floor support and the vertical straps used at one end of the frame stacks,
FIG. 42 is a schematic sectional end view along line [0064] 42-42 of FIG. 39, showing two meshed frame stacks on a common floor support and the vertical straps used at a further end of the frame stacks,
FIG. 43 is a schematic side view of a plurality of stacked frames having support means according to the invention, showing two meshed frame stacks on a common floor support and the diagonal straps used to secure the frames during transport, [0065]
FIG. 44 is a schematic sectional end view along line [0066] 44-44 of FIG. 43, showing two meshed frame stacks on a common floor support and the diagonal straps used at one end of the frame stacks,
FIG. 45A is a schematic side view of a further embodiment of a third stacking means according to the invention, [0067]
FIG. 45B is a further schematic side view of the frame stacking means of FIG. 45A, [0068]
FIG. 45C is a schematic top view of the frame stacking means of FIG. 45A, [0069]
FIG. 45D is a schematic bottom view of the frame stacking means of FIG. 45A, [0070]
FIG. 46A is a schematic side view of yet a further embodiment of a third stacking means according to the invention, [0071]
FIG. 46B is a further schematic side view of the frame stacking means of FIG. 46A, [0072]
FIG. 46C is a schematic top view of the frame stacking means of FIG. 46A, and [0073]
FIG. 46D is a schematic bottom view of the frame stacking means of FIG. 46A.[0074]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. [0075] 1 to 5, a stack 1 of frames 5 is shown. The frames are, for example, vehicle frames stacked for transport or storage. Each individual frame 5 has a forward end 6 and a rearward end 7. Each frame comprises at least two frame rails (as is shown in FIG. 3) with the appropriate cross-members as dictated by the particular vehicle application. The frame stack 1 is placed upon a floor support 10, which may be a substantially rectangular construction, as shown in FIG. 3, and which is made of metal profiles. A metal floor support is stronger than a wood pallet, which is traditionally used as a base for frame stacks, and retains its dimensions during stress and weather changes better.
The floor support preferably has [0076] first pillars 20 on which the frame stack 1 is placed. A preferred embodiment of the invention involves a floor support having four first pillars, placed towards the four corners of the substantially rectangular floor support 10, together with four lower frame support rods 28 (see FIG. 1A). The frames 5 are stacked with each forward end 6 adjacent (above or below) the front end of a neighbouring frame. Between two adjacent frames is a first stacking means 100 arranged at the forward end, to space the two frames apart a pre-determined distance. Further, between two adjacent frames is a second stacking means 200 arranged at the rearward end 7, also to space the two frames apart a pre-determined distance.
At the top of the topmost frame of the frame stack, is preferably a third stacking means [0077] 300 arranged, the function of which will be described later. The entire frame stack 1 is resting on fourth stacking means 400, which are arranged between the bottom-most frame and the first pillars 20 of the floor support 10. The fourth stacking means is preferably made of a resilient material, which is capable of absorbing the force exerted on it by the weight of the frame stack, for example poly-urethane. The fourth stacking means will be described in more detail later.
As is shown in FIGS. 2 and 2A, the third stacking means [0078] 300 are arranged to allow a tie-down rope 30, or similar, to be attached to one side of the floor support 10, run over the frame stack 1 via the third stacking means, and fastened to the opposite side of the floor support, so that the tie-down rope is resting on the top part of the third stacking means. In this way, the tie-down rope will not make contact directly with any frame 5 of the frame stack 1, and will thus not be able to scrape or rub against the frame, thereby ruining the frame finish.
As an example, ten frames may be stacked onto each floor support, preferably meshing two frame stacks as shown in FIGS. 1A and 2A. Any number of frames can be stacked, however, the actual number being determined by available space. For transportation in a regular truck trailer, or similar, six frames stacked on each other may be used (FIGS. 1 and 2). For container transport, the meshed frame stacking alternative is advantageous. The first frame stack would then have the front of its frames facing the opposite direction of the front of the frames of the second frame stack, and the second frame stack would be located parallel to the first frame stack but having one frame rail inside the first frame stack. Also, the frames of the second frame stack would be vertically offset with respect to the frames of the first frame set, so that the second frames would be generally half-way between the frames of the first frame set, in a vertical direction. Thus, [0079] second pillars 20′ are arranged on the floor support 10, to accommodate the second frame stack. In FIGS. 1A and 2A, furthermore show features relating to a stackable floor support 20, having floor support pillars 26, which are used when the floor supports are sent back to the frame factory/assembly plant. A more detailed description of these features will follow below (see FIGS. 29 to 38).
The first stacking [0080] means 100 is shown in more detail in FIGS. 6 to 13. The first stacking means has a first body 101, preferably made of durable plastic, for example a polyurethane elastomer such as a polyether. The first body has an upper end 110, a lower end 120 and a middle part 130. The upper end is preferably generally conical, forming an upper substantially flat surface 150, which is angled to cooperate with the lower surface of a frame. The lower end 120 is also generally conical, forming a lower substantially flat surface 160. The first body 101 further has a first support rod 140 centrally arranged in the first body in a longitudinal direction of the first body. The first support rod protrudes from the lower surface 160 a predetermined distance and is preferably made of a metal or metal alloy material. In the upper surface 150 is a first cavity 170 arranged to accept the protruding part of an adjacent first support means 100 or, as will be described later, the third stacking means 300. Further, the first stacking means 100 preferably has a first indication means 190 arranged on its outer surface, to indicate in what direction the first stacking means should be arranged on a frame 5. The first body 101 of the first stacking means is preferably made of a certain colour, differing from the colour of the second stacking means 200, to facilitate the selection of stacking means (for proper location) during the stacking operation.
The [0081] first support rod 140 preferably has a first end 145′ and a second end 146. The first end is arranged at the lower part of the first support rod, and the second end is arranged at the upper part of the first support rod. Further, the first support rod has a lower flattened portion 147 and an upper generally cylindrical portion 148. During a preferred method of manufacture of the first stacking means 100, a first support rod 140 is placed in a mould into which the material for the first body 101 is inserted. The first body is thus formed directly around the first support rod. Also, the protruding portion of the first support rod is preferably coated with the same material as makes up the first body 101, to form a sleeve 195 around the protruding part of the first support rod. In this way, the protruding part of the first support rod will be less prone to scratch or otherwise damage the frame 5 during assembly of the frame stack 1.
To further facilitate the insertion of the [0082] first support rod 140 into the first cavity 170 of an adjacent stacking means or similar, the first end 145′ of the first support rod is preferably tapered, with a similarly tapered cover 145 of durable material. Arranged on the upper flat surface 150, or on the lower flat surface 160 (not shown) are preferably cutouts 180, which correspond to elements on the frames 5, if necessary. Advantageously, the sleeve 195 around the protruding part of the first support rod 140 has an enlarged portion 196 arranged adjacent the lower end 120 of the first body 101, to prevent the first stacking means 100 from moving horizontally in the mounting hole in the frame 5. Thus, the stack of frames 1 will be more stable, and the wear on the frames during transport will be further minimized.
When two or more first stacking means [0083] 100 are inserted on frames 5 for forming a frame stack 1, the protruding portion of the first support rod 140 of the lowermost first stacking means will be inserted through the corresponding opening in the lowest-most frame and into the fourth stacking means 400 (which will be described later). The first end 145′ of the first support rod will thus rest on the fourth stacking means. The lower surface 160 of the lowermost first stacking means 100 will not make any contact with the frame 5, the length of the protruding portion of the first support rod is chosen to prevent this.
A [0084] second frame 5 is placed on top of the lowermost frame, and a further first stacking means 100 is inserted through the corresponding opening in the second frame and into the first cavity 170 of the lowermost first stacking means, where the first end 145′ of the further first stacking means will make contact with the second end 146 of the lowermost first support rod of the first stacking means. The second frame will rest on the upper surface 150 of the lowermost first stacking means 100 with the weight of the second frame being transferred to the support rod of the lowermost stacking means via the first body of the lowermost stacking means. A third frame, placed on top of the further first stacking means, will rest on the upper surface 150 of the further first stacking means in a similar way. The lower surface 160 of the further first stacking means 100 will not make any contact with the second frame 5, the length of the protruding portion of the first support rod is chosen to prevent this. Further first stacking means are put onto each frame as required in a similar way, to complete the frame stack 1. Naturally, second stacking means 200 will have to be put at the second end 7 of the frames, to keep the frames substantially horizontal (see below). Thus, the individual frames will rest on upper surfaces of each respective stacking means, but the total weight of the frames will only be transferred via the support rods of the stacking means.
The second stacking means [0085] 200 is shown in more detail in FIGS. 14 to 19. The second stacking means has a second body 201, preferably made of the same durable plastic as that used for the first stacking means 100. The second body has an upper end 210, a lower end 220 and a middle part 230. The upper end is preferably generally conical, forming an upper substantially flat surface 250, which is angled to cooperate with the lower surface of a frame. The lower end 220 is also generally conical, forming a lower substantially flat surface 260. The second body 201 further has a second support rod 240 centrally arranged in the second body in a longitudinal direction of the body. The second support rod protrudes from the lower surface 260 a predetermined distance a predetermined distance and is preferably made of a metal or metal alloy material. In the upper surface 250 is a second cavity 270 arranged to accept the protruding part of an adjacent second support means 200 or, as will be described later, the third stacking means 300. Further, the second stacking means 200 preferably has a second indication means 290 arranged on its outer surface, to indicate in what direction the second stacking means should be arranged on a frame 5. The second body 201 of the second stacking means is preferably made of a certain colour, differing from the colour of the first stacking means 100, to facilitate the selection of stacking means during the stacking operation.
The [0086] second support rod 240 preferably has a first end 245′ and a second end 246. The first end is arranged at the lower part of the second support rod, and the second end is arranged at the upper part of the second support rod. Further, the second support rod has a lower flattened portion 247 and an upper generally cylindrical portion 248. During a preferred method of manufacture of the second stacking means 200, a second support rod 240 is placed in a mould into which the material for the second body 201 is inserted. The second body is thus formed directly around the second support rod. Also, the protruding portion of the second support rod is preferably coated with the same material as makes up the second body 201, to form a sleeve 295 around the protruding part of the second support rod. In this way, the protruding part of the second support rod will be less prone to scratch or otherwise damage the frame 5 during assembly of the frame stack 1. To further facilitate the insertion of the second support rod 240 into the second cavity 270 of an adjacent stacking means or similar, the first end 245′ of the second support rod is preferably tapered, with a similarly tapered cover 245 of durable material. Arranged on the upper flat surface 250, or on the lower flat surface 260 (not shown) are preferably cutouts 280, which correspond to elements on the frames 5, if necessary. Advantageously, the sleeve 295 around the protruding part of the second support rod 240 has an enlarged portion 296 arranged adjacent the lower end 220 of the second body 201, to prevent the second stacking means 200 from moving horizontally in the mounting hole in the frame 5. Thus, the stack of frames 1 will be more stable, and the wear on the frames during transport will be further minimized.
When two or more second stacking means [0087] 200 are stacked on frames 5 to form a frame stack 1, the protruding portion of the second support rod 240 of the lowermost second stacking means will be inserted through the corresponding opening in the lowest-most frame and into the fourth stacking means 400 (which will be described later). The first end 245′ of the second support rod will thus rest on the fourth stacking means. The lower surface 260 of the lowermost second stacking means 200 will not make any contact with the frame 5, the length of the protruding portion of the second support rod is chosen to prevent this. A second frame 5 is placed on top of the lowermost frame, and a further second stacking means 200 is inserted through the corresponding opening in the second frame and into the second cavity 270 of the lowermost second stacking means, where the first end 245′ of the further second stacking means will make contact with the second end 246 of the lowermost second support rod of the second stacking means. The second frame will rest on the upper surface 250 of the lowermost second stacking means 200, and a third frame, placed on top of the further second stacking means, will rest on the upper surface 250 of the further second stacking means. The lower surface 260 of the further second stacking means 200 will not make any contact with the second frame 5, the length of the protruding portion of the second support rod is chosen to prevent this. Further second stacking means are put onto each frame as required in a similar way, to complete the frame stack 1.
In a preferred embodiment, the first and second stacking means are identical to save on manufacturing costs. In most cases, though, the shape of the frames to be stacked will make it necessary to have a first stacking means with a certain angle to its top surface and a second stacking means with a different angle to its top surface. The different angles of the respective top surfaces will be determined by the shape of the frame at the part of the frame where the top surface of the respective stacking means makes contact with the frame. [0088]
A third stacking means [0089] 300 is shown in FIGS. 20 to 22. The third stacking means has a third body 301, made of a similar material as the bodies of the first and second stacking means. The third body has a substantially flat lower surface 360 and a hemi-cylindrical upper surface 350. The upper surface has protruding ridges 330 at each end. The upper surface with the two ridges thus form a saddle over which a tie-rope (see FIG. 2) can be strapped. Further, the third stacking means 300 has a third support rod 340, for insertion into the first cavity 170 of a first stacking means 100 or the second cavity 270 of a second stacking means 200. The third support rod has an upper portion 348, which is encased in the third body 301, and a protruding portion, which is preferably covered in a similar way as the protruding portions of the first and second support rods. Similarly, the third support rod 340 has a lower end 345′, which is tapered and has a tapered cover 345.
A further embodiment of a third stacking means [0090] 300′ is shown in FIGS. 45A to 45D. The further embodiment of the third stacking means has a third body 301′, made of a similar material as the bodies of the first and second stacking means. The third body preferably has tapering sides and has a substantially flat lower surface 360′ and a substantially flat cut-out upper surface 350′. The upper surface has protruding ridges 330′ at each end. The upper surface with the two ridges thus form a saddle over which a tie-rope (see FIG. 2) can be strapped. Further, the further embodiment of the third stacking means 300′ has a third support rod 340′, for insertion into the first cavity 170 of a first stacking means 100 or the second cavity 270 of a second stacking means 200. The third support rod has an upper portion 348′, which is encased in the third body 301′, and a protruding portion, which is preferably covered in a similar way as the protruding portions of the first and second support rods. Similarly, the third support rod 340′ has a lower end 345′″, which is tapered and has a tapered cover 345″.
Yet a further embodiment of a third stacking means [0091] 300′ is shown in FIGS. 46A to 46D. This embodiment of the third stacking means is similar in all respects to the embodiment shown in FIGS. 45A to 45D, except that one side of the third body 301′ is cut off fairly close to the third support rod 340′, to provide extra clearance when fitting the third stacking means in locations on the frame where there is little available space. All other reference numbers are the same as for FIGS. 45A to 45D.
In FIG. 23 is shown the fourth stacking means [0092] 400 as it is resting on a pillar 20. The pillar has walls 21, which carry a base plate 24 at the upper end of the pillar. On the base plate is a holder 25 arranged to receive the fourth stacking means 400. The holder has two substantially vertical long sides 22 and two substantially vertical short sides 23, forming an enclosed space substantially corresponding to the outer dimensions of the fourth stacking means. The fourth stacking means is, thus, preferably removably attachable to the pillar, and further has a bottom surface 420, which contacts the base plate 24. Alternatively, the fourth stacking means is cast into the holder 25 with the holder already attached to the base plate and the pillar 20. The pillar is then attached to the floor support 10, for instance by welding. The fourth stacking means further has an upper surface 430 with a central third cavity 410. The third cavity receives the first or second support rods from a first or second stacking means, as required to anchor the frame stack 1. The support rod thus rests on the base plate 24, with only the bottom-most frame resting on the fourth stacking means upper surface 430. The combined weight of the stacked frames is absorbed by the stacked support rods, terminating in the base plate for further transmission to the floor support via the pillars.
The first stacking means and the second stacking means are thus self supporting on their respective support pins, when used as described for stacking frames. The material used for the respective bodies and coating of the respective support pins has to be corrosion resistant, abrasion resistant, strong and generally elastic. Also, the stacking means according to the invention are lighter than the known stacking means, and can be easily and safely handled with one hand by a user. The different stacking means have to be able to work with the existing shape, openings, holes etc. of the frames. A different shape body and a different length support pin is therefor envisioned as a part of the invention, for adapting the stacking means to a particular frame. No other structural support, other than the first, second, third and fourth stacking means and the floor support, is necessary to allow the stacking of frames as described above. Generally, a floor support having four pillars is used, one pillar towards every corner of the frames. [0093]
FIGS. [0094] 29 to 38 show a stackable floor support 10, having the aforementioned floor support pillars 26. In addition, the floor support preferably has removable lower frame support rods 28 arranged in lower frame support holders 29, to stabilize the frame stack 1 during lateral movements of the floor support/frame stack. In order to make it possible to economically transport the floor supports, without stacked frames, the floor supports are stacked one on top of the other during transport. The second pillars 20′ are removed from their pillar holders 27, and the lower frame support rods 28 are also removed from their lower frame support rod holders 29, to lower the stacking profile height of each floor support 10. Each floor support pillar 26 has a guide means 30 arranged at the bottom of the floor support pillar, to facilitate alignment of one floor support being stacked on top of another floor support. Thus, the floor supports 10 are stacked with the floor support pillars 26 aligned with each other, and the top of the floor support pillar of the lower floor support being inserted into the guide means 30 of the upper floor support. Thus, the stacked floor supports occupy very little space, compared to shipping non-stacked floor supports or floor supports randomly stacked. A random stacking of floor supports may also damage the floor supports, which is avoided using stacked floor supports according to the invention.
To prevent the stacked frames from shifting during transport, for instance if the frame stack is subjected to an upwards rapid movement which could dislodge one or more frames from the stacking means, a multitude of straps are used to tie the frame stack to the [0095] floor support 10. FIGS. 39 to 42 show examples of advantageous vertical straps used in the invention. The term vertical is used to describe straps that run mainly up and down, as opposed to diagonal. In addition to end straps tied over the third stacking means 300 and tied to the floor support 10, further vertical straps 501, 502, 503, 504 are used in the general middle portion of the frame stacks. As is shown in FIG. 40, first and second middle straps, 503 and 504 respectively, are tied to the floor support and loop over the respective second frame of each frame stack. Further middle straps, 501 and 502 respectively, tie one side of each frame stack together by looping directly over on of the frame rails of one stack.
FIG. 41 shows the location of extra diagonal end straps [0096] 610, 611 and 612, 613 for each frame stack, respectively. These straps help prevent any sideways movement of the individual frames of one frame stack, with respect to the longitudinal direction of the frames. The straps loop over top and bottom frames of one frame stack only, i.e. they do not attach to the floor support 10.
FIG. 42 shows the location of extra vertical end straps [0097] 506 and 508 respectively. These straps advantageously form a looped end 508′ (loop ends for vertical end strap 506 not shown), which preferably is attached around a strut 10′ attached to the floor support 10 and on which the pillars 20 are supportedly mounted.
Examples of longitudinal [0098] diagonal straps 601, 602, 603, 604 and 604′ respectively, are shown in FIGS. 43 and 44. The diagonal straps are preferably looped over a cross-brace 10″ of the floor support 10 at a first end of the diagonal strap, the cross-brace running transversely to the longitudinal direction of the floor support. The other end of the diagonal strap is looped over an end cross-bar 700 attached to each end of each frame 5. The cross-bar could be a permanent cross-bar intended to be a part of the finished vehicle, or a temporary cross-bar mounted to the frame during the transport only.
It is important, for all straps, to torque straps evenly from side to side (longitudinally or transversely) to provide straight frame stacks. This is advantageous because a straight stack distributes the weight evenly on the stacking means thus minimizing the wear on the stacking means, and also requires less space inside a container or other transport space. [0099]
Further, it is important for the fit of the stacking means pin in the frame hole to be as “snug” as possible, to provide a rattle-free frame stack. This minimizes wear on the stacking means and the risk of wearing the urethane coating off the stacking means. To achieve this required fit, the cover thickness of the plastic material on the stacking means is regulated when coating the stacking means. A too tight fit, on the other hand, makes removal of the stacking means from the frame hole unnecessary difficult. [0100]
An alternative embodiment of first and second stacking means will be made of one-piece durable plastic material earlier described for the bodies. The one-piece stacking means will have an outer shape identical to the one shown in the drawings, but without any metal support rod. The protruding portion is instead formed from the same material as makes up the body portion, advantageously reinforced with, for example, fibres. Thus, this embodiment of a stacking means is manufactured in one operation in a mould. [0101]
The floor support according to the invention is advantageously blocked inside a transport container from sliding on a floor of the container, using blocks according to known techniques. [0102]
To facilitate the transport of stacking means during the return transport of the empty floor supports, each floor support preferably has pans located at the bottom of the supports (not shown). The individual stacking means are placed on one of the pans and are thus prevented from being lost during the return transport. [0103]
It will be appreciated that the above description relates to the preferred embodiments by way of example only. Many variations on the invention will be obvious to those knowledgeable in the field, and such obvious variations are within the scope of the invention as described and claimed, whether or not expressly described. [0104]

Claims

What is claimed as the invention is:

1. A system for stacking vehicle frames on a floor support comprising:

a floor support, having a plurality of upwardly reaching support pillars for resting a bottom frame of said frames to form a stack of frames,

stacking means, having a resilient body and a support pin inserted into holes at an end of said frames so that said stacking means separate one of said frames from another of said frames in said stack of frames a predetermined distance.

2. The system as recited in claim 1, wherein said stacking means comprises:

a non-metallic body with an upper end, forming an upper surface, which is angled to cooperate with a lower surface of a said frames, and a lower end, forming a lower surface, which is angled to cooperate with an upper surface of a said frames;

a support rod coated with a plastic material and centrally arranged in said body in a longitudinal direction of said body, said support rod being inserted into holes of said frames.

3. The system as recited in claim 2, wherein said body is made from a plastic material.

4. The system as recited in claim 3, wherein said body is made from a polyurethane elastomer.

5. The system as recited in claim 4, wherein said body is made from a polyether.

6. The system as recited in claim 1, wherein said stacking means comprise

first stacking means, having a first resilient body and a first support pin inserted into holes at a first end of said frames so that said first stacking means separate one of said frames from another of said frames in said stack of frames a first predetermined distance, and

second stacking means, having a second resilient body and a second support pin inserted into holes at a second end of said frames so that said second stacking means separate one of said frames from another of said frames in said stack of frames a second predetermined distance.

7. The system as recited in claim 1, wherein said system comprises

a third stacking means, having a third resilient body and a third support rod inserted into holes on top of a top frame of said stack of frames for providing a resting surface for a strap.

8. The system as recited in claim 2, wherein said system comprises

9. The system as recited in claim 1, wherein said system comprises

a fourth stacking means, arranged on said support pillars and having a resilient body for providing a resilient support for said bottom frame of said stack of frames.

10. The system as recited in claim 2, wherein said system comprises

11. The system as recited in claim 1, wherein said system comprises vertical straps arranged in a general middle portion of said frame stack.

12. The system as recited in claim 11, wherein said vertical straps comprise first and second middle straps tied to said floor support and looped over a respective second frame of each said frame stack.

13. The system as recited in claim 12, wherein said vertical straps comprise third and fourth middle straps tying one side of each said frame stack together by looping directly over one frame rail of one said frame stack.

14. The system as recited in claim 1, wherein said system comprises diagonal end straps for each said frame stack, said diagonal end straps looping over top and bottom frames of one said frame stack only without being attached to said floor support.

15. The system as recited in claim 1, wherein said system comprises vertical end straps forming a looped end attached around a strut attached to said floor support.

16. The system as recited in claim 1, wherein said system comprises longitudinal diagonal straps, looped over a cross-brace of said floor support at a first end of said diagonal straps, said cross-brace running transversely to a longitudinal direction of said floor support, an opposite end of said diagonal straps being looped over an end cross-bar attached to each end of each said frame.