Modular Crate Assembly and Its Use

The present invention generally relates to a modular crate assembly for the handling and transportation of goods. The present invention also relates to the use of the modular crate assembly for freight logistics, warehousing, transport and/or shipment purposes.

Modular pallet architectures and crate solutions are known as such in the art.

International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1 in the name of the present Applicant, the content of which is incorporated herein by reference, disclose such a modular pallet architecture allowing formation of nested pallet assemblies of varying sizes using a set of individual pallet modules of different dimensions, including e.g. a unit-size pallet module, a medium-size pallet module and a large-size pallet module. In one embodiment, all pallet modules may especially exhibit a generally square shape. the medium-size pallet module and large-size pallet module each having a size that is an integer multiple of the size of the unit-size pallet module. Other embodiments are however contemplated.

In accordance with International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, all relevant pallet modules forming part of a given assortment of pallet modules can selectively be assembled one with the other to form a pallet assembly of varying size. The pallet modules disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1 share a substantial number of common features, including:

The first and second lateral flanges form a first part of a mating system that is configured to allow lateral nesting of multiple pallet modules within one another. The first and second lateral flanges are in effect configured to cooperate and mate with the first and second lateral grooves, which form another corresponding part of the relevant mating system.

The first to fourth toggle latch components are provided on the upper side of the main structural body at least partly within corresponding recesses formed below the upper surface of the upper side of the main structural body.

In accordance with a preferred embodiment disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, the main structural bodies of the unit-size pallet module, the medium-size pallet module and the large-size pallet module, respectively, each exhibit a square shape. The length of the main structural body of the medium-size pallet module is preferably twice the length (or “unit length”) of the unit-size pallet module, while the length of the main structural body of the large-size pallet module is preferably four times the unit length. In this context, the number of toggle latch components along each side increases as a function of the increase in dimensions of the pallet module, namely, from one per side for the unit-size pallet module, to two per side for the medium-size pallet module, and four per side for the large-size pallet module.

The first and second toggle latch components are each configured to cooperate and interlock with the third and fourth toggle latch components, respectively, of another similar pallet module of the nested pallet assembly, to form releasable toggle latches, allowing each pallet module to be secured to or released from another pallet module of the assortment. More specifically, each of the first and second toggle latch components comprises a spring-loaded latch element with a moveable latch section that extends outwardly to cooperate with the third, respectively fourth toggle latch component of another pallet module, each of the third and fourth toggle latch components consisting here of a catch element comprising a catch section. The spring-loaded latch element is manually actuatable and further comprises a handle section that is mechanically linked to the moveable latch section to allow manual actuation of the latch element. Each releasable toggle latch is thus formed of two connectable or disconnectable sections, one being provided on one pallet module of the pallet assembly, and the other on the other, adjacent pallet module of the pallet assembly.

The foot structure may consist of a fixed foot structure comprising one or more foot elements that are made integral with the main structural body. Advantageously, the main structural bodies are structured to exhibit one or more corresponding depressions on the upper side allowing stacking of multiple pallet modules one on top of the other.

The aforementioned modular pallet architecture provides unprecedented benefits, especially in terms of freight logistics and environmental sustainability. In particular, the underlying structure and concept of the aforementioned modular pallet structure is simple, yet provides substantial flexibility in the pallet assemblies that can be built on the basis of the relevant assortment of pallet modules. The dimensions and structure of the relevant pallet modules can be selected to boost efficiency and ease of use. The pallet modules can be assembled (and disassembled) very easily and quickly, and the dimensions thereof can be optimized to ensure that substantially all of the available shipment space can be exploited, thereby drastically reducing waste as well as packaging and shipment costs. In addition, the pallet modules are designed to be reused many times, thereby ensuring greater sustainability and reducing carbon footprint as a result compared to existing pallet solutions.

By way of preference, as further disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, the pallet modules may advantageously be configured to be compatible with and enable the so-called Physical Internet (PI) global logistics model, which is also referred to as the Physical Internet Initiative (see in particular “Towards a Physical Internet: Meeting the Global Logistics Sustainability Grand Challenge”, Benoit Montreuil, January 2011, CIRRELT-2011-03, which publication is incorporated herein by reference in its entirety). The Physical Internet encapsulates physical objects in physical packets or containers (referred to as “TT-containers”). The aforementioned modular pallet architecture is in effect a functional enabler of this encapsulation principle. “Encapsulation” is one of the three main requirements of the Physical Internet global logistics model; two additional requirements are “Protocols” and “Interfaces”. The aforementioned modular pallet architecture thus acts as an enabler to the implementation of these two additional requirements in that it allows for the standardization of pallet modules for different sizes and load requirements, and provides for added flexibility. enabling reorganization of the entire freight logistics at distribution centres (or nodes). In this context, each pallet module may further include a smart tag (based e.g. on RFID or GPS technology) providing identification and traceability of each pallet module, a further functional enabler of the Physical Internet global logistics model. This smart tag in particular helps ensuring the identification, integrity, routing, conditioning, monitoring, traceability and security of each π-container and further enables distributed handling, storage and routing automation.

Modular container concepts are also discussed in “Modular Design of Physical Internet Transport, Handling and Packaging Containers”, Benoit Montreuil et al., March 2017, Progress in Material Handling Research: 2014, 13, MHI, 2015, International Material Handling Research Colloquium. 978-1-882780-18-3, HAL Id: hal-01487239 (https://hal-mines-paristech.archives-ouvertes.fr/hal-01487239), as well as in “Containers for the Physical Internet: requirements and engineering design related to FMCG logistics”, Christian Landschützer et al., Oct. 29, 2015, Logistics Research 8, 8 (2015) (https://doi.org/10.1007/s12159-015-0126-3).

International (PCT) Publication No. WO 90/08067 A1 discloses a modular system for making containers including reusable panels for the side walls of the containers, the side wall panels having horizontal edge portions providing for guided vertical staking of the panels. The side wall panels also have fastening devices adjacent the upright corners of the containers, with the end portions of the panels overlapping each other in a series in one direction around the perimeter of the containers, and with the fastening devices including fastening plates in series overlapping each other in the opposite direction around the perimeter of the containers.

U.S. Pat. No. 3,584,757 A discloses a modular container comprising a base panel for carrying cargo thereon and a plurality of wall panels positionable on the base panel to form sides and a top portion of the container for enclosing the cargo. Each of the base and wall panels have a bevelled edge portion on its outer edges and is designed to form mitered joints between assembled panels. Each of the panels have sockets formed through and normal to the bevelled surfaces to allow insertion of a plurality of fasteners that are each removably fastenable in a press-fit relationship within the sockets, thereby interlocking panels one with the other.

U.S. Pat. No. 7,909,000 B1 discloses a universal panel member that can be connected with other identical universal panel members to forming feeder structures for the feeding of forage materials to animals, such as horses. The universal panel members to provide a floor with ground engaging legs and an upright wall surrounding the floor into which forage material can be placed for access by the animals feeding therefrom.

U.S. Patent Publication No. US 2009/0266813 A1 discloses a collapsible container for containing goods, including a liquid and/or solid/liquid mixture, which collapsible container is configured to be assembled and disassembled manually without the use of tools. The container includes a plurality of upright panels coupled to a base by their bottom portions. Each panel of a first type is flanked along its opposing upright edges by a pair of adjacent panels of a second type. Each of the edges of each of the panels is coupled by an edge joining assembly to one of the edges of one of the flanking panels. The edge joining assembly comprises a first elongated edge joining member having a longitudinal channel with alternating partially enclosed portions and substantially unenclosed portions and a second elongated edge joining member having longitudinally extending spaced apart locking members. Each unenclosed portion is configured to receive a locking member, which are slid longitudinally within the longitudinal channel into an adjacent partially enclosed portion.

There remains a need to further expand upon the aforementioned modular pallet architectures and modular container concepts, namely, provide a suitable solution to fully encase goods inside a dedicated storage space.

Modular crate assemblies are generally known in the art but the known solutions typically fail to provide sufficient flexibility in terms of the ability to adapt the configuration and size of the relevant crate assembly to the size of the pallet and to the size of the relevant goods.

International (PCT) Publication No. WO 2021/072492 A1 for instance discloses a modular crate assembly that is based on a combination of dedicated panel and base components that can only be assembled in one particular way and therefore lack the desired flexibility.

There therefore remains a need for a suitable modular crate assembly.

A general aim of the present invention is to provide an improved solution for freight logistics and industrial packaging of goods.

More specifically, an aim of the invention is to provide a modular crate assembly having improved modularity.

Furthermore, an aim of the present invention is to provide such a solution that fully enables the aforementioned Physical Internet (PI) global logistics model, namely, such a solution that adequately enables the encapsulation principle and fulfils the requirement for an interconnected logistic system in a complex multi-model transport environment.

Yet another aim of the invention is to provide such a solution that is cost-efficient to implement, run and maintain.

A further aim of the invention is to provide such a solution that ensures flexibility in how crate assemblies can be built and assembled.

Yet another aim is to provide such a solution that allows reduction of the environmental footprint by reducing the amount of wood waste and inherent COemissions resulting from the known packaging solutions that follow the traditional linear economy principle or that are based on a suboptimal circular economy principle.

These aims and others are achieved thanks to the solutions defined in the claims.

There is accordingly provided a modular crate assembly for the handling and transportation of goods according to claim, namely, such a modular crate assembly including a bottom pallet part and a sidewall consisting of four side panels that are mounted onto the bottom pallet part. The four side panels are modular and formed of multiple side panel modules that are assembled and mutually joined at corners to form the sidewall, each side panel module comprising first and second lateral mating interfaces. The first and second lateral mating interfaces are configured to allow direct joining of two adjacent side panel modules along two perpendicular planes to form the corners of the sidewall. The first and second lateral mating interfaces are further configured to allow direct or indirect joining of two adjacent side panel modules along a same plane to form each side panel. In addition, the first lateral mating interface is provided with a male or female connecting structure configured to mate with a corresponding female or male connecting structure provided on the second lateral mating interface.

The invention allows for improved efficiency in that it provides for a fully reusable crate assembly that can be used to replace conventional single-use crate solutions, thereby reducing total cost of ownership from a packaging cost perspective and favouring implementation of a circular economy principle. At the same time, the invention allows for an optimization of the volume and weight of the entire crate solution for a given shipment space, thereby reducing transport costs.

Advantageous and/or preferred embodiments of the modular crate assembly form the subject-matter of dependent claimsto.

Also claimed is the use of the modular crate assembly of the invention for freight logistics, warehousing, transport and/or shipment purposes.

Further advantageous embodiments of the invention are discussed below.

The present invention will be described in relation to various illustrative embodiments. It shall be understood that the scope of the invention encompasses all combinations and sub-combinations of the features of the embodiments disclosed herein.

As described herein, when two or more parts or components are described as being connected, secured or coupled to one another, they can be so connected, secured or coupled directly to each other or through one or more intermediary parts.

In the context of the present invention, the expressions “bottom pallet part”, “pallet module” and “pallet assembly” are understood to refer to self-supporting platforms configured to allow the handling and transportation of goods, as used in particular for freight logistics, warehousing, transport and/or shipment purposes. As discussed below, the bottom pallet part of the crate assembly of the invention may advantageously consist of a pallet assembly built of one or multiple pallet modules which are nested laterally within and interlock with one another to form a platform that is adapted in particular to support and allow transport and shipment of goods or equipment, be it by ground, sea or air transportation.

The invention will be described in relation to various embodiments of a modular crate assembly (or modular crate system) comprising a modular bottom pallet part that advantageously consists of one or more pallet modules that are assembled one with the other to form pallet assemblies of varying configurations and sizes. The bottom pallet part as discussed herein is preferably based on the modular pallet architecture disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, but it will be appreciated that the present invention is in effect applicable to any modular pallet architecture that would provide similar modularity and benefits.

As far as the configuration and physical interconnection of the pallet modules are concerned, one may accordingly refer to the full disclosure of International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, which publications are incorporated herein by reference. Ideally, each pallet module includes, as shown e.g. in, (i) a mating system configured to allow lateral nesting of another pallet module to form the nested pallet assembly, and (ii) a securing system configured to allow the pallet module to be secured to or released from another pallet module of the nested pallet assembly. The interconnectable pallet modules may once again be of different sizes.

toA-B are illustrative of a first embodiment of a modular crate assembly for the handling and transportation of goods in accordance with the invention, which modular crate assembly is generally designated by reference sign CR.show the modular crate assembly CR in a fully assembled state, including a bottom pallet part PL and a sidewall consisting of four side panels SP that are mounted onto the bottom pallet part PL. In the illustrated example, the modular crate assembly CR further comprises a top part

TP mounted onto an upper portion of the four side panels SP, thereby forming a closed space around the relevant goods.shows the modular crate assembly CR in a partly disassembled state, with the top part TP being removed from the upper portion of the sidewall. In other embodiments, the top part TP could in effect be omitted to form an open crate assembly.

In the illustrated example, the bottom pallet part PL consists of an assembly of four individual pallet modules PLM, as shown in greater detail in, that are designed in accordance with the modular pallet architecture disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1. More specifically, each pallet module PLM is a unit-size pallet module and the four pallet modules PLM are assembled in a two-by-two configuration to form the bottom pallet part PL. Each pallet module PLM comprises a main structural bodyexhibiting a generally quadrilateral peripheral borderA with first to fourth lateral sides. First and second lateral flanges,extend outwardly from the peripheral borderA of the main structural bodyalong the first and second lateral sides. The main structural bodyalso exhibits first and second lateral grooves,extending inwardly from the peripheral borderA of the main structural body, along the third and fourth lateral sides. Each of the first and second lateral grooves,is configured to receive a corresponding one of the first and second lateral flanges,of another pallet module PLM, so that the first, respectively, second lateral flange,of said other pallet module PLM nests laterally within the first, respectively second lateral groove,, as depicted in.

On the underside of each pallet module PLM, as shown in, there is provided a foot structure FT that advantageously forms an integral part of each pallet module PLM to create clearances between the bottom pallet part PL and the ground to ensure suitable handling of the crate assembly CR by means of forklifts and the like. In other embodiments, the foot structure could consist of individual foot elements removably secured to the underside of each pallet module, as further disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1.

By way of preference, and in accordance with the principle disclosed in International (PCT) Publications Nos. WO 2020/141492 A1 and WO 2020/141494 A1, each pallet module PLM further includes a set of releasable connection devicesA,B (see) configured to selectively secure each pallet module PLM to adjacent pallet modules PLM. In the illustrated example, the releasable connection devices include releasable latch componentsA,B and are preferably toggle latch components including pairs of mutually engageable latch elements each comprising a movable latch elementA and a catch elementB. In this case, the releasable latch componentsA,B are configured to allow manual latching of the pallet modules PLM. In other embodiments, one could however contemplate the use of any other suitable type of releasable connection devices, such as releasable connection devices configured to allow remote securement of the pallet modules PLM using e.g. motorized latch components or any other adequate, remotely actuatable securement mechanism.

Also visible inare four cover elements CMthat are designed to cover the, otherwise exposed, first and second lateral flanges,that extend along first and second lateral sides of the bottom pallet part PL that coincide with the first and second lateral sides of the pallet modules PLM. These cover elements CMare also visible, partly or entirely, in. Each of the cover element CMis provided with a catch elementB designed to cooperate with the movable latch elementA of the associated pallet module PLM.

The top part TP likewise includes an assembly of multiple top modules TPM, namely, in the illustrated example, an assembly of four individual top modules TPM, as shown in. The top modules TPM are in effect designed along essentially the same principle as the pallet modules PLM. More specifically, each top module TPM is a unit-size module and the four top modules TPM are assembled in a two-by-two configuration to form the top part TP. Each top module TPM comprises a main structural bodyexhibiting a generally quadrilateral peripheral borderA with first to fourth lateral sides. First and second lateral flanges,extend outwardly from the peripheral borderA of the main structural bodyalong the first and second lateral sides. The main structural bodyalso exhibits first and second lateral grooves,extending inwardly from the peripheral borderA of the main structural body, along the third and fourth lateral sides. Each of the first and second lateral grooves,is configured to receive a corresponding one of the first and second lateral flanges,of another top module TPM, so that the first, respectively, second lateral flange,of said other top module TPM nests laterally within the first, respectively second lateral groove,, as depicted in.

Also visible inare four cover elements CMthat are similar to the cover elements CMof the bottom pallet part PL, which cover elements CMare likewise designed to cover the, otherwise exposed, first and second lateral flanges,that extend along first and second lateral sides of the top part TP and coincide with the first and second lateral sides of the top modules TPM. These cover elements CMare also visible, partly or entirely, in. In effect, the dimensions of the bottom pallet part PL and top part TP may advantageously be chosen so as to match one another, thereby allowing for the use of identical cover elements CM, CMat the bottom and top of the modular crate assembly CR.

While not specifically shown, each of the top modules TPM may advantageously be provided with a set of a releasable connection devices, as previously discussed with respect to the bottom pallet part PL, configured to selectively secure each top module TPM to adjacent top modules TPM. Such releasable connection devices may likewise be releasable latch components such as toggle latch components including pairs of mutually engageable latch elements each comprising a movable latch elementA and a catch elementB as shown in, allowing manual latching of the top modules TPM. In other embodiments, one could however once again contemplate the use of any other suitable type of connection devices, including releasable connecting devices configured to allow remote securement of the top modules TPM using e.g. motorized latch components or any adequate, remotely actuatable securement mechanism. The same applies to the cover elements CMwhich may likewise be provided with a catch elementB designed to cooperate with the movable latch elementA of the associated top module TPM.

In accordance with the invention, the four side panels SP are modular and formed of multiple side panel modules SPM that are assembled and mutually jointed at corners to form the sidewall. In the illustrated example, each side panel SP consists of an assembly of four adjacent, unit-size side panel modules SPM assembled in a two-by-two configuration, namely, adjacent side panel modules SPM that are arranged side by side as well as one on top of the other in a same plane. In other words, in the illustrated example, a total of sixteen side panel modules SPM are used to form the sidewall of the depicted modular crate assembly CR. One will however appreciate that, depending on the size of the goods, the sizes of the bottom pallet part PL, top part TP, and sidewall could vary, and that each side panel SP could especially include more than two adjacent side panel modules SPM distributed horizontally and/or vertically.

As shown in the partially exploded view of, the top part TP is secured to the upper portion of the sidewall by means of a set of securing elements including, in the illustrated example, a set of sixteen screws(also partly visible in) and associated bolts. More specifically, the screwsare inserted through corresponding mounting holes-(see) provided in the top modules TPM and associated cover elements CM, as well as corresponding mounting holes,(see) provided in the upper portion of each side panel module SPM.

In the illustrated example (see especially), each top module TPM includes four pairs of mounting holes,,,, namely, first and second pairs of mounting holes,extending vertically through the first and second lateral flanges,, along the first and second lateral sides, and third and fourth pairs of mounting holes,extending vertically through the main structural body, across the first and second lateral grooves,, along the third and fourth lateral sides. Each cover element CMincludes a corresponding pair of mounting holesthat match the location of the associated pair of mounting holes, respectivelywhen the cover element CMis positioned on the relevant lateral flange,.

In the illustrated example, as shown especially in, the upper portion of each side panel module SPM is provided with first and second pairs of mounting holes,that are distributed to match the location of the mounting holes-when assembled to the top part TP. More specifically, the position of the first pair of mounting holesis selected to match that of mounting holes, resp., while the position of the second pair of mounting holesis selected to match that of mounting holes, resp.. Corresponding mounting holes,are also provided on the lower portion of each side panel module SPM, as shown e.g. in, to allow each side panel module SPM to be secured to another side panel module SPM located immediately below or to the bottom pallet part PL. Attachment of adjacent side panel modules SPM in the vertical direction is likewise ensured by a set of screws, inserted through matching pairs of mounting holes/, resp./, and bolts, visible in, similar to those used for securing the top part TP to the upper portion of the sidewall.