Storage and supply apparatus and method

Abstract

A container (100) for storing discrete flooring articles, such as carpet tiles, comprises a base (110) for receiving a stack of articles (not shown) and a perimeter wall (120), upstanding from the bas

Description

The present invention relates to a storage and supply apparatus and a method of storage and supply, and is concerned particularly, although not exclusively, with an apparatus for storing and supplying textile articles, such as carpet tiles and planks, and with an associated method. When storing flooring articles, such as carpet tiles and planks, it is necessary to preserve their shape and flatness, whilst protecting their edges and corners and ensuring that they remain free from dust, dirt, moisture and other contaminants . Currently, in the case of carpet tiles and planks, this is done by placing the tiles in cardboard boxes, stacking the boxes on a pallet and then wrapping the stack using filmic material. The wrapped stacks are then stored in a warehouse before shipping to a customer. There are several problems with the above approach. Firstly, during their time in the warehouse, the cardboard boxes suffer damage. This can be caused in a number of ways, but examples include where a stack of boxes is unwrapped so that some boxes can be removed, either for supply to a customer or else for stock-taking purposes. The remaining boxes in the stack must be re-wrapped, but this is often overlooked. Airborne moisture can then affect the cardboard, compromising its structural integrity. Furthermore, the stack may now be uneven or misaligned, and pressure from later stacking on top of the affected boxes will result in crushing of the boxes, and consequent damage to the tiles. Additionally, prolonged storage of unwrapped boxes leads to them becoming soiled and unsuitable for delivery to the customer . Re-boxing of the tiles for any reason, and re-wrapping of the stacks, is expensive, wasteful, time-consuming and environmentally unsound. Tiles that have become bent out of plane, or whose edges or corners have been damaged, will be rejected by the fitter as they will not be able to form a neat, continuous finish during installation, which adds to waste and cost. Embodiments of the present invention aim to provide an apparatus and method for storing and supplying flooring articles, in which the above problems are at least partly addressed. The present invention is defined in the attached independent claims, to which reference should now be made. Further, preferred features may be found in the sub-claims appended thereto . According to one aspect of the present invention, there is provided a container for storing discrete flooring articles, the container comprising a base for receiving a stack of articles and a perimeter wall, upstanding from the base, wherein the wall has one or more retaining portions at an upper edge thereof, for receiving a lower portion of another such container stacked thereon. The container preferably has a support member spaced from the sidewall for supporting the base of another such container stacked thereon. The support member may include at least one dividing portion for separating plural stacks of articles on the base. The support member may be located substantially centrally on the base . The container is preferably rectangular in plan. Preferably the retaining member is located at a corner of the container. In a particularly preferred arrangement, the container has four corners, and each corner has a retaining member. The container preferably has one or more handles, more preferably located on or proximate to a periphery of the container, for lifting the container. The container may have a lid, which lid may have one or more lid projections for bearing against separate stacks of articles. The lid projections are preferably located on an underside of the lid and are preferably arranged in use each to press against a respective stack of articles within the container. In a preferred arrangement, the lid projections correspond to dividing portion(s) of the support member, so that individual stacks are separated by the dividing portion(s) and held separately in place by the lid proj ections . In a preferred arrangement, the container is made from wood, metal and / or a plastics material, such as polypropylene. The flooring articles may comprise carpet tiles. The container may be used in a method of storage and / or of supply of flooring articles. According to another aspect of the present invention, there is provided a method of storing discrete flooring articles, the method comprising placing at least one stack of articles in a container comprising a base for receiving a stack of articles and a perimeter wall, upstanding from the base, wherein the wall has one or more retaining portions at an upper edge thereof, for receiving a lower portion of another such container stacked thereon. In a preferred arrangement, the method comprises storing the articles in the container as a plurality of stacks of articles, wherein a support member, spaced from the sidewall and for supporting the base of another such container stacked thereon, divides the stacks. The method may comprise stacking a plurality of containers containing the articles, such that at least a portion of one container is at least partly retained by a part of the container beneath it. The method may comprise keeping the articles in place within the container by a container lid, which lid may have one or more lid projections for bearing against separate stacks of articles. The lid projections are preferably located on an underside of the lid and are preferably arranged in use each to press against a respective stack of articles within the container. In a preferred arrangement, the lid projections correspond to dividing portion(s) of the support member, so that individual stacks are separated by the dividing portion(s) and held separately in place by the lid proj ections . The method preferably comprises a method of storing textile flooring articles, such as carpet tiles and planks. The invention also includes a method of supplying flooring articles, comprising transporting the articles in a container according to any statement herein. The method may comprise recovering the containers and reusing them after delivery. The invention may include any combination of the features or limitations referred to herein, except such a combination of features as are mutually exclusive, or mutually inconsistent. A preferred embodiment of the present invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings, in which: Figure 1 is a schematic perspective view of a container for storing discrete flooring articles, in accordance with an embodiment of the present invention; Figure 2 is a schematic plan view of the container of Figure 1; and Figure 3 is a schematic perspective view of several of the containers of Figures 1 and 2 in stacked formation. A container, or crate, for discrete flooring articles, such as carpet tiles or planks, is shown schematically in Figures 1 and 2, generally at 100. The container is a cuboid shape having a base 110, four side walls 120, four corner retainers 130 and a support / divider portion 140 located on the base. The container, which is of plastics material, such as polypropylene, is dimensioned to accommodate four separate stacks 150 of floor tiles, with each tile being typically 50cm x 50cm or, in the case of planks, typically 25cm x 100cm. A typical thickness would be in the range 0.45 cm to 0.7 cm. In Figure 1, the container is shown without tiles. Figure 2 shows the intended positions of the four stacks of tiles 150 in broken lines. In use, four stacks of tiles are placed inside the container in four designated quarters of the base. The stacks are divided and kept apart by the support / divider portion 140, which, in this embodiment, also has the function of supporting the base of another container stacked on top (not shown in Figure 1). In this example, the support / divider 140 is of cruciform shape, as there are four separate quarter portions of the base for receiving four stacks of tiles. However, in other embodiments, for example where longer, narrower tile shapes are to be accommodated, such as is the case with planks, the support / divider can be of a different shape and indeed there may be several such support / divider portions. The support / divider is substantially the same height as the walls of the container 100, and enables the load of a stacked container above (not shown) to be supported evenly, so that its base does not tend to sag over time. At each corner of the container, a substantially L-shaped retainer 130 extends upwardly of the perimeter wall 120. The purpose of the retainers is to hold a lower portion of another identical container stacked on top, so that the stacked containers are not able to slide laterally over one another and remain stable. The container may also include one or more lifting handles (not shown) arranged at a periphery of the container, for lifting the container when it is loaded with articles or empty. Figure 3 shows schematically such a stack, generally designated as S. A lid 160 rests on top of the stack and is held in place by the retainers 130. The lid may have, on its underside, shaped panels or projections (not shown) that correspond with the positions of the stacks of tiles or planks beneath, in order to assist in keeping the uppermost tiles in their respective stacks. The stack S rests on a known wooden pallet P in this example. Discrete flooring articles stored in containers according to embodiments of the invention are protected from 5 contamination and safe from damage by compression or impact. The containers may be stacked and re-used many times, without themselves becoming damaged. Whilst endeavouring in the foregoing specification to draw 10 attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and / or shown in the drawings, whether or not particular emphasis 15 has been placed thereon.

Claims

1. A container for storing discrete flooring articles, the container comprising a base for receiving a stack of articles and a perimeter wall, upstanding from the base, wherein the wall has one or more retaining portions at an upper edge thereof, for receiving a lower portion of another such container stacked thereon.

2. A container according to Claim 1, wherein the container has a support member spaced from the sidewall for supporting the base of another such container stacked thereon.

3. A container according to Claim 2, wherein the support member includes at least one dividing portion for separating plural stacks of articles on the base4. A container according to any of Claims 1-3, wherein the container is rectangular in plan and retaining members are located at each corner of the container.

5. A container according to any of the preceding claims, wherein the container has a lid, which lid has one or more lid projections for bearing against separate stacks of articles .

6. A container according to Claim 5, wherein the or each lid projections are preferably located on an underside of the lid and are arranged in use each to press against a respective stack of articles within the container.

7. A container according to Claim 6 when dependent upon Claim 3, wherein the lid projections correspond to dividing portion (s) of the support member, so that individual stacks are separated by the dividing portion(s) and held separately in place by the lid projections.

8. A method of storing discrete flooring articles, the method comprising placing at least one stack of articles in a container comprising a base for receiving a stack of articles and a perimeter wall, upstanding from the base, wherein the wall has one or more retaining portions at an upper edge thereof, for receiving a lower portion of another such container stacked thereon.

9. A method according to Claim 8, wherein the method comprises storing the articles in the container as a plurality of stacks of articles, wherein a support member, spaced from the sidewall and for supporting the base of another such container stacked thereon, divides the stacks.10.. A method according to Claim 8 or 9, wherein the method comprises stacking a plurality of containers containing the articles, such that at least a portion of one container is at least partly retained by a part of the container beneath it.

11. A method according to any of Claims 8-10, wherein the method comprises a method of storing textile flooring articles, such as carpet tiles and / or planks.5 12. A method of supplying flooring articles, comprisingtransporting the articles in a container according to any of Claims 1-7.

13. A method according to Claim 12, comprising recovering 10 the containers and reusing them after delivery.

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