Shipping container for manufactured panels

Abstract

A shipping container (16) for one or more panels can be configured in an assembled state or a stowed state. The shipping container includes a pallet (18) with a storage surface and a plurality of post mounts (52). In the assembled state, posts (20) are attached to the post mounts, end bars (22) are attached to the posts, and side bars (24) are also attached to the posts to define a storage space adjacent to the storage surface. Support dunnage (34) on the pallet is located in the storage space. In the stowed state, the end bars are attached to the post mounts and define a stowage space adjacent to the storage surface.

Description

Shipping Container for Manufactured PanelsCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a claims priority to U.S. provisional patent application 63 / 764843, filed February 28, 2025, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] This invention relates to a reusable container for transporting manufactured panels such as photovoltaic modules.BACKGROUND

[0003] Photovoltaic modules typically are manufactured at a manufacturing facility and transported to a second site for installation. In order to safely and efficiently transport multiple photovoltaic modules, a shipping container that may be loaded onto a truck or other vehicle is normally used. It would be desirable to have an improved shipping container.DESCRIPTION OF DRAWINGS

[0004] Fig. 1 is a rear perspective view of an example photovoltaic panel.

[0005] Fig. 2 is a front perspective view of a shipping container, adapted for the transport of multiple photovoltaic panels.

[0006] Fig. 3 is a front plan view of the shipping container illustrated in Fig. 2.

[0007] Fig. 4 is a side plan view of the shipping container illustrated in Fig. 2.

[0008] Fig. 4a is an enlarged view of a portion of the shipping container illustrated in Fig. 4.

[0009] Fig. 5 is a perspective view of the shipping container in the illustrated in Fig. 2, shown in a stowed state.

[0010] Fig. 6 is a perspective view of a post from the shipping container illustrated in Fig. 2.

[0011] Fig. 7 is a perspective view of an end bar from the shipping container illustrated in Fig. 2.

[0012] Fig. 8 is an enlarged, side plan view of one end of the end bar illustrated in Fig. 6.

[0013] Fig. 9 is a view similar to Fig. 8, with an end latch shown in an extended position.

[0014] Fig. 10 is a perspective view of a side bar from the shipping container illustrated in Fig. 2.

[0015] Fig. 11 is an enlarged, side plan view of one end of the side bar illustrated in Fig. 10.

[0016] Fig. 12 is a view similar to Fig. 11, with a side latch shown in an extended position.

[0017] Fig. 13 is a perspective view of the shipping container illustrated in Fig. 2, shown seated on a second shipping container.

[0018] Fig. 14 is a perspective view of the shipping container illustrated in Fig. 2, shown in a partially assembled state.

[0019] Fig. 15 is a side view of the partially assembled shipping container illustrated in Fig. 14.

[0020] Fig. 16 is a perspective view of the shipping container illustrated in Fig. 2, shown in a second partially assembled state.

[0021] Fig. 17 is a perspective view of the shipping container illustrated in Fig. 2, shown in a third partially assembled state.

[0022] Fig. 18 is a perspective view of the shipping container in the stowed state illustrated in Fig. 5, shown seated on a plurality of stowed shipping containers.

[0023] Fig. 19 is a perspective view of a second example of an end bar.

[0024] Fig. 20 is an enlarged view of a portion of the end bar illustrated in Fig. 19.

[0025] Fig. 21 is an enlarged side view of an end latch from the end bar illustrated in Fig. 20.

[0026] Fig. 22 is a perspective view of a second example of a post.

[0027] Fig. 23 is a cross-sectional view of the end bar illustrated in Fig. 19 attached to the port illustrated in Fig. 22.

[0028] Fig. 24 is an enlarged perspective view of a third example of a post.

[0029] Fig. 25 is a side view of an end bar attached to the post illustrated in Fig. 24.

[0030] Fig. 26 is a side view of a side bar attached to the post illustrated in Fig. 24.DETAILED DESCRIPTION

[0031] Referring to Fig. 1, there is illustrated a rear perspective view of an example of a photovoltaic device, indicated generally at 10. The photovoltaic device 10 includes a photovoltaic module 12 that is made of glass panels. Two steel rails 14 are attached to one sideof the photovoltaic module 12. The illustrated photovoltaic device 10 does not include a frame around the edge of the photovoltaic module 12. As a result, it is desirable to protect the edges of the photovoltaic module 12 from damage when the photovoltaic device 10 is transported from a manufacturing facility to an installation location.

[0032] Referring to Fig. 2, there is illustrated a front perspective view of a first example of a shipping container, illustrated generally at 16. A front plan view and a side plan view of the shipping container 16 are illustrated in Figs. 3 and 4, respectively. The shipping container 16 is illustrated in an assembled state in Fig. 2, wherein the shipping container 16 is adapted to hold a plurality of photovoltaic devices 10. The shipping container 16 includes a pallet 18, posts 20, end bars 22, and side bars 24. The assembled shipping container 16 defines a storage space, indicated generally at 26 between the pallet 18, posts 20, end bars 22, and side bars 24. The illustrated shipping container 16 is collapsable and is illustrated in a stowed state in Fig. 5. In the stowed state, the components of the shipping container 16 are placed on the pallet 18 and the shipping container 16 is more compact than in the assembled state. This allows the shipping container 16 to be more easily transported from the installation location to the manufacturing facility for reuse.

[0033] The illustrated pallet 18 is made of steel but may be made of other suitable materials. The pallet 18 includes a pallet body 28 that includes a storage surface 30 and an opposite seat surface 32. The pallet 18 includes support dunnage 34 that is located on the storage surface 30. The illustrated pallet 18 includes two support dunnage 34 but may include other desired number of support dunnage 34. The support dunnage 34 are shown in a storage position in Figs. 2-4, wherein the support dunnage 34 extends from the storage surface 30 in a storage direction 36 that is perpendicular to the storage surface 30. The support dunnage 34 in the storage position serves to hold photovoltaic devices 10 in place on the shipping container 16, as described below.

[0034] The support dunnage 34 is located in a stack direction 38 across the pallet 18. The illustrated stack direction 38 is parallel to the storage surface 30. The illustrated support dunnage 34 is made of rubber but may be made of any suitable compliant material. The support dunnage 34 includes a plurality of first cradles 40 and second cradles 42. The first cradles 40 are V-shaped channels in the dunnage 38, and each includes a support end 40a and a wider open end 40b that is located farther from the storage surface 30 than the support end 40a. Similarly, the second cradles 42 are V-shaped channels in the dunnage 38, and each includes a support end 42aand a wider open end 42b that is located farther from the storage surface 30 than the support end 42a. As shown in Fig. 4, the support ends 40a of the first cradles 40 are located in a first plane 44 that is parallel to the support surface 30. The support ends 42b of the second cradles 42 are located in a second plane 46 that is also parallel to the support surface 30. The second plane 46 is farther from the support surface 30 than the first plane 44.

[0035] As shown in Fig. 2, the sides of the first cradles 40 and the second cradles 42 are open on both sides in a panel direction 48 that is parallel to the storage surface 30 and is perpendicular to the stack direction 38. Additionally, as shown in Fig. 4, each first cradle 40 on one of the support dunnage 34 is aligned in the panel direction 48 with one of the first cradle 40 on the other of the support dunnage 34. Similarly, each second cradle 42 on one of the support dunnage 34 is aligned in the panel direction 48 with one of the second cradle 42 on the other of the support dunnage 34.

[0036] The first cradles 40 and the second cradles 42 are arranged in an alternating configuration in the stack direction 38. Additionally, the first cradles 40 and the second cradles 42 are uniformly spaced in the stack direction 38. The separation 50 in the stack direction 38 between the support end 40a and 40b of each adjacent first cradle 40 and second cradle 42 is the same across the support dunnage 34.

[0037] The pallet 18 includes a plurality of post mounts 52 and each post mount 52 is adapted to hold one post 20. The illustrated pallet 18 includes four post mounts 34, one located near each corner of the illustrate pallet 18. However, the pallet 18 may include other desired number of post mounts 34. Four posts 20 are illustrated on the pallet 18 in installed positions in respective post mounts 34 in Figs. 2-4. The post 20 in the installed position extends from the pallet 18 in the storage direction 36.

[0038] An enlarged perspective view of the post 20 is illustrated in Fig. 6. The post includes a post body 54, a post pin 56. and an alignment pin 58. The post body 54 is made of steel and extends along a post axis 60 between a first end 62 and a second end 64. The illustrated post body 54 has a substantially square cross-sectional shape perpendicular to the post axis 60 but may have other suitable shape. The post pin 56 is located at the first end 62 of the post body 54. The illustrated post pin 56 has a substantially circular cross-sectional shape perpendicular to the post axis 60 but may have other suitable shape. As shown in Fig. 6, the post pin 56 is located partially inside the post body 54 and includes an exposed part 66 that extends outside of the postbody 54. As shown in Figs. 2-4, when the post 20 is installed on the pallet 18, the post 20 is positioned adjacent to the post mount 52 in the storage direction 48, and the exposed part 66 of the post pin 56 is positioned inside the post mount 52. The post body 54 is then located on the post mount 52, which has substantially the same cross-sectional shape perpendicular to the post axis 60 as the post body 54. It should be appreciated that when the illustrated post 20 is in the installed state on the pallet 18, the post axis 60 is parallel to the storage direction 36. However, the post 20 may have some other desired orientation relative to the pallet 18. The alignment pin 58 is located at the second end 64 of the post body 54 and serves to align the shipping container 16 when it is stacked, as described below. The illustrated alignment pin 58 is made of steel but may be made of other suitable material.

[0039] As shown in Fig. 6, the post 20 includes end bar mounts 68 and side bar mounts 70. The illustrated end bar mounts 68 are located on one side of the post body 54 and the side bar mounts 70 are located on an adjacent side of the post body 54. The end bar mounts 68 and the side bar mounts 70 are adapted to attach the end bars 22 and the side bars 24 to the posts 20, as described below.

[0040] Fig. 7 is a perspective view of one of the end bars 22. The end bar 22 includes an end bar body 72 that extends from a first end 74 to a second end 76. The illustrated end bar 22 is made of steel but may be made of other suitable material. The end bar 22 includes an end latch, indicated generally at 78, at the first end 74 and a similar end latch 78 at the second end 76. As both end latches 78 are similar, only one will be described in detail.

[0041] Fig. 8 is an enlarged side plan view of the first end 74 of the end bar 22. The end bar 22 includes the end latch at the first end 74. The end latch 78 includes a hook 80 and a pin 82. The hook 80 is movable relative to the first end 74 between a retracted position illustrated in Fig. 8 and an extended position illustrated in in Fig. 9. The illustrated hook 80 is located between two flanges 84 on the end bar 22. The two flanges are connected by a span 86. A cover 88 that is substantially parallel to the span 86 is also connected to the two flanges 84 near the first end 74 of the end bar 22. The hook 80 is located between the span 86 and the cover 88. Two rivets 90 extend through the cover 88, the hook 80, and the span 86 to hold the hook 80 for limited movement relative to the first end 74. The hook 80 includes a tab 92 that an operator can grasp in order to slide the hook 80 between the retracted position and the extended position.

[0042] The pin 82 is movable relative to the first end 74 between a retracted position illustrated in Fig. 8 and an extended position illustrated in in Fig. 9. The pin 82 is located in a sleeve 94. The illustrated sleeve 94 is attached to one of the flanges 84 but may be located in another suitable location. When the pin 82 is in the extended position, it extends from the sleeve 94 and past the first end 74 of the end bar 22. When the pin 82 is in the retracted position, it is located on one side on the first end 74 and does not extend past the first end 74. Additionally, the pin 82 is located within the sleeve 94. The end latch 78 includes a spring 96 that biases the pin 82 to the extended position. The illustrated spring 96 is located within the sleeve 94. A stop 98 is attached to the pin 82 and extends out of the sleeve 94. The operator can grasp the stop 98 in order to slide the pin 82 from the extended position to the retracted position.

[0043] In order to attach the end bar 22 to the posts 20, the hook 80 is moved to the retracted position, and the pin 82 is moved to the retracted position, as illustrated in Fig. 8. The end bar 22 is then placed in an initial position relative to the post 20, wherein the first end 74 of the end bar 22 is adjacent to the end bar mount 68 on the post 20. The hook 80 is then moved to the extended position, this causes part of the hook 80 to enter a hook hole 100 on the post 20. The first end 74 of the end bar 22 is then moved opposite the storage direction 36 relative to the post 20 to an installed position so that the hook 80 engages the post body 54 and the hook 80 supports the weight of the end bar 22. When the first end 74 of the end bar 22 is in the installed position relative to the post 20, the pin 82 is aligned with a pin hole 102 on the post 20. The spring 96 pushes the pin 82 partially into the pin hole 102, which prevents the first end 74 from being moved relative to the post 20. The pin 82 acts as a position assurance, as the pin 82 enters the pin hole 102 when the first end 74 is properly positioned in the installed position relative to the post 20. Additionally, the pin 82 acts as a retainer, as the pin 82 engaged with the pin hole 102 prevents the hook 80 from being raised from the installed position. The second end 76 of the end bar 22 is attached to another of the post 20 in a similar manner and will not be described in detail.

[0044] As shown in Fig. 8, when the hook 80 is in the retracted position, the hook 80 is located between the two flanges 84, the span 86 and the cover 88. This creates a first box 150 around the hook 80 that protects the hook 80 from damage. Additionally, in normal operation, the hook 80 is kept in the retracted position until the first end 74 is in the initial position relative to the post 20. The hook 80 is then moved to the extend position into the hook hole 100 on thepost 20, to the position illustrated in Fig. 3 wherein the post body 54 creates a second box 152 that protects the hook 80 from damage. As a result, the hook 80 is protected from damage from outside impacts.

[0045] Fig. 10 is a perspective view of one of the side bars 24. The side bar 24 includes a side bar body 104 that extends from a first end 106 to a second end 108. The illustrated side bar 24 is made of steel but may be made of other suitable material. The side bar 24 includes a side latch, indicated generally at 110, at the first end 106 and a similar side latch 110 at the second end 108.

[0046] Fig. 11 is an enlarged side plan view of the first end 106 of the side bar 24 with the side latch 110 visible. The side latch 110 is similar to the previously described end latch 78 in construction and operation, and not all parts of the side latch 110 will be described in detail. The side latch 110 includes a side hook 112 that includes two retainers 114. The side bar 24 includes two side flanges 116 that are connected by a side span 118. The side latch 110 includes a side sleeve 120 that is attached to the side span 118, and one of the side flanges 120 ends at a distance from the first end 106 to provide space for the side sleeve 120 to be attached to the side span 118.

[0047] The side bar 24 is attached to the posts 20 similarly to how the previously described end bar 22 is attached to the posts 20. In order to attach the side bar 24 to the posts 20, the side hook 112 is moved to a retracted position and a side pin 122 is moved to a retracted position, as illustrated in Fig. 11. The side bar 24 is then placed in an initial position relative to the post 20, wherein the first end 106 of the side bar 24 is adjacent to the side bar mount 70 on the post 20. The side hook 112 is then moved to the extended position, this causes part of the side hook 112 to enter a side hook hole 124 on the post 20. The first end 106 of the side bar 24 is then moved opposite the storage direction 36 relative to the post 20 to an installed position so that the side hook 112 engages the post body 54 and the side 112 supports the weight of the end bar 22. As shown on Fig. 6, the side hook hole 124 include an intermediate bridge 126, and one of the two retainers 114 engages the bridge 126 when the first end 106 of the side bar 24 is in the installed position. When the first end 106 of the side bar 24 is in the installed position relative to the post 20, the side pin 122 is aligned with a side pin hole 128 on the post 20. A spring 130 pushes the side pin 122 partially into the side pin hole 128. which prevents the first end 106 from being moved relative to the post 20. The second end 108 of the side bar 24 is attached to another of thepost 20 in a similar manner and will not be described in detail. The side hook 112 is protected from damage in both the retracted and extended positions, similar to the previously described first box 150 and second box 152.

[0048] As shown in Figs. 2 and 4, the illustrated shipping container 16 includes four side bars 24, with two side bars 24 located on each of two opposite sides. As shown in Fig. 6, the post 20 includes two side bar mounts 70, to accommodate two attached side bars 24. As shown in Fig. 2, the side bars 24 located farther from the pallet 18 include side dunnage 132 that extends from the side bar body 104 into the storage space 26. The side dunnage 132 serves to hold photovoltaic devices 10 in place on the shipping container 16, as described below. The illustrated side dunnage 34 is made of rubber but may be made of any suitable compliant material. The side dunnage 34 includes a plurality of side cradles 134. The side cradles 134 are Y-shaped channels in the side dunnage 132. The sides of the side cradles 134 are open in the storage direction 36. Other than the side dunnage 132, all of the illustrated side bars 24 have similar features and are interchangeable on the shipping container 16.

[0049] Fig. 13 is a perspective view of the assembled shipping container 16 illustrated supported on a second shipping container 1016. The second shipping container 1016 has similar components as the shipping container 16 and refence to any component of the second shipping container 1016 will use the same reference number as the similar component on the shipping container, increased by 1000. As shown, the second shipping container 1016 is holding a plurality of photovoltaic devices 1010 in a storage space 1026. Each of the photovoltaic devices 1010 is seated in one of a first cradle (not shown) or second cradle 1042 in a support dunnage 1034. Additionally, each of the photovoltaic devices 1010 is located in one of a side cradle (not shown) in a side dunnage 1132 on opposite sides of each of the photovoltaic devices 1010 (only one is visible in Fig. 13). Each photovoltaic device 1010 engages the support dunnage 1034 and the side dunnage 1132 in order to hold the photovoltaic device 1010 in place relative to the shipping container 1016.

[0050] The shipping container 16 is supported on the second shipping container 1016, and the second shipping container 1016 includes posts 1020 that each engage one of the post mounts 52 on the shipping container 16. As shown in Figs. 2-4, the post mounts 52 on the pallet 18 extend from the storage surface 30 toward the seat surface 32. As previously described, the alignment pin 58 is located at the second end 64 of the post body 54 and serves to align theshipping container 16 when it is stacked. The second shipping container 1016 includes alignment pins 1058, and when the shipping container 16 is stacked on the second shipping container 1016, as shown in Fig. 13, part of each one of the alignment pins 1058 is positioned inside respective ones of the post mounts 52. The alignment pin 1058 engages the respective post mount 52 in order to hold the shipping container 16 in place relative to the second shipping container 1016. Also, the weight of the shipping container 16 is supported by the posts 1020 on the second shipping container 1016.

[0051] The shipping container 16 includes lift holes 138 that extend through the pallet body 28. The lift holes 138 allow a device such as a forklift (not shown) to lift and move the shipping container 16 to a desired location. The illustrated pallet 18 includes four lift holes 138, two that extend parallel to the stack direction 38, and two that extend parallel to the panel direction 48. The lift holes 138 are located so that the support dunnage 34 is located at least partially in the storage direction 36 of one or more lift holes 138. This allows the weight of the photovoltaic device 10 loaded on the shipping container 16 to be transferred to the lift.

[0052] As previously described, each of the posts 20 is separately attachable to the pallet 18, and each of the end bars 22 and side bars 24 are separately attachable to the posts 20. This allows the operator to partially assemble the shipping container 16 in a desired one of multiple possible configurations. Fig. 14 is a schematic illustration of the partially assembled shipping container 16, shown with two posts 20 attached to the pallet 18 at adjacent comers, and one end bar 22 attached on one side. Fig. 15 is a side view of the partially assembled shipping container 16 from Fig. 14, shown with a plurality of photovoltaic devices 10 in the storage space 26. As illustrated in Fig. 15, the pallet 18 is held at an angle to the horizonal. such that the stack direction 38 is not parallel to the ground. This causes each of the photovoltaic devices 10 in the storage space 26 to lean against an adjacent photovoltaic device 10 and against the attached end bar 22. The weight of photovoltaic devices 10 can be further supported by a load backrest 140 adjacent to the partially assembled shipping container 16. The configuration illustrated in Figs. 14 and 15 may be used when the shipping container 16 is initially loaded with photovoltaic devices 10, as well as when photovoltaic devices 10 are being removed from the shipping container 16 for installation.

[0053] Fig. 16 is a schematic illustration of the partially assembled shipping container 16, shown with four posts 20 attached to the pallet 18 at adjacent comers, and two end bars 22attached on opposite sides. Fig. 17 is a schematic illustration of the partially assembled shipping container 16, shown with three posts 20 attached to the pallet 18 at adjacent comers, one end bar 22 attached, and side bars 24 attached on one side. The individual components of the shipping container 16 are removable from the pallet 18 such that when the shipping container 16 is delivered to the installation location, the shipping container 16 is adapted to be configured by the operator in a way that is suitable for the location and the work being performed.

[0054] Referring back to Fig. 5, the shipping container 16 is illustrated in the stowed state. The shipping container 16 is adapted to be configured to the stowed state by the operator in order to facilitate returning the shipping container 16 to the manufacturing facility. In the stowed state, the components of the shipping container 16 are placed on the pallet 18 and the shipping container 16 is more compact than in the assembled state. This allows the shipping container 16 to be more easily transported from the installation location to the manufacturing facility for reuse. The shipping container 16 includes secondary end bar mounts 142 that are used to attach the end bars 22 to the pallet 18 in respective stowed positions. The illustrated secondary end bar mounts 142 are located on the post mounts 52. When the end bars 22 are attached to the illustrated secondary end bar mounts 142, the end bars 22 are located closer to the storage surface 30 of the pallet 18 and are generally adjacent to the support dunnage 34. The support dunnage 34 is also illustrated in a stowed position in Fig. 5. The illustrated support dunnage 34 is attached to the pallet 18 for relative movement between the storage position illustrated in Figs. 2-4, and the stowed position illustrated in Fig. 5. The illustrated support dunnage 34 is attached to the pallet body 28 for relative rotation about a dunnage axis 144. The support dunnage 34 in the storage position extends farther from the storage surface 30 than the support dunnage 34 in the stowed position does.

[0055] The end bars 22 include stow brackets 146, and as illustrated in Fig. 5, the stow brackets 146 are adapted to accommodate the posts 20 and the side bars 24, in order to retain the posts 20 and the side bars 24 in place relative to the pallet 18 when the shipping container 16 is in the stowed state. Additionally, when in the stowed state, a stowage space, indicated generally at 148, is defined on the storage surface 30. The illustrated stowage space 148 is defined between the end bars 22 and the support dunnage 34. The posts 20 and the side bars 24 may be placed in the stowage space 148. Additionally, other items to be transported with the shipping container 16 may be placed in the stowage space 148.

[0056] Fig. 18 illustrates the shipping container 16 in the stowed state, stacked with the second shipping container 1016 in a stowed state, and a plurality of additional shipping containers 2016 in their respective stowed states. As shown in Figs. 2-4, the shipping container 16 includes lower seats 154 on the same side of the pallet 18 as the seat surface 32. Each lower seat 154 is located adjacent to one of the post mounts 52. As shown in Fig. 4a, the post mount 52 includes a seat end 156 that is offset in the storage direction 36 from the seat surface 32, defining a seat space 158. When the shipping container 16 is stacked on the second shipping container 1016 in the stowed state, as illustrated in Fig. 18, each post mount 1052 on the second shipping container 1016 extends into one of the seat spaces 158 and engages one of the post mounts 52 on the shipping container 16. The weight of the shipping container 16 is transferred through the post mounts 52 to the post mounts 1052 on the second shipping container 1016. The weight of the shipping container 16 keeps it in place on the second shipping container 1016.

[0057] Fig. 19 is a perspective view of a second example of an end bar 160. The end bar 160 is similar to the previously described end bar 22 but includes an end latch 162 that is different from the previously described end latch 78. The end bar 160 includes an end bar body 164 that extends from a first end 166 to a second end 168. The illustrated end bar 160 is made of steel but may be made of other suitable material. The end bar 160 includes the end latch 162 at the first end 166 and a similar end latch 162 at the second end 168. As both end latches 162 are similar, only one will be described in detail.

[0058] Fig. 20 is an enlarged view of a first end 162, showing the end latch 162. Fig. 21 is an enlarged, side plan view of the end latch 162. The end latch 162 includes two latch arms 170 that are attached together for relative movement. The illustrated latch arms 170 are attached by a pivot 172 and rotatable relative to each other. The illustrated pivot 172 is a bushing and a rivet that extends through each of the latch arms 170 but any suitable connector may be used. Each latch arm 170 includes a latch hook 176 that extends from the latch arm 170 in a respective outward direction 178. The outward direction 178 for each latch arm 170 is the direction away from the other latch arm 170. Each latch arm 170 includes a latch stop 180 that extends from the latch arm 170 in the outward direction 178. The latch stop 180 is located closer to the pivot 172 than the latch hook 176 is. The end latch 162 includes a latch spring 182 that biases the two latch arms 170 apart from each other, in their respective outward directions 178. The latch spring 182 biases the end latch 162 to a latched state, illustrated in Fig. 21.

[0059] As shown in Fig. 20, the end bar 160 includes two flanges 184 that are connected by a span 186. A retainer 188 that is substantially parallel to the span 186 is also connected to the two flanges 184 near the first end 166 of the end bar 160. The end latch 162 is located between the two flanges 84 on the end bar 160, the end latch 162 is also located between the span 186 and the retainer 188. Each flange 184 includes a guide hole 190 and each of the latch stops 180 on the end latch 162 extends through a respective guide hole 190. The guide hole 190 has a length 192 in a latch direction 194 that extends away from the first end 166 of the end bar 160. The length 192 is larger than the latch stop 180, and the latch stop 180 is able to be moved in the latch direction 194 relative to the first end 166. The end latch 162 is illustrated in an extended position in Fig. 20, wherein each of the latch hooks 176 of the end latch 162 is not located between the flanges 184. The latch spring 182 biases the two latch arms 170 in their respective outward directions 178 and each latch arm 170 engages a respective one of the flanges 184, this holds the end latch 162 in position relative to the first end 168. The operator can press the latch stops 180 inwardly, opposite their respective outward direction 178, to move the end latch 162 to an open state. The end latch 162 is then movable in the latch direction 194 to a retracted position, wherein each of the latch hooks 176 is located between the flanges 184. The latch spring 182 biases the latch arms 170 in their outward direction 178 to put the end latch 162 in the latched state, wherein the latch arms 170 engage the respective flange 184 and the end latch 162 is held in position relative to the first end 168.

[0060] Fig. 22 is a perspective view of a post 196 that is similar to the previously described post 20, but the post 196 is adapted for use with the end bar 160. In order to attach the end bar 160 to the post 196, the end latch 162 is in the retracted position and the end bar 160 is then placed in an initial position relative to the post 196, wherein the first end 166 of the end bar 160 is adjacent to an end bar mount 198 on the post 196. The end latch 162 is then moved to the open state and the end latch 162 is moved to the extended position, this causes the latch hooks 176 to enter a hook hole 200 on the post 196. The operator then releases the latch stops 180 and the latch arms 170 are biased in their respective outward directions 178 by the latch spring 182 and the end latch 162 is in the latched state. Fig. 23 is a cross-sectional view of the end bar 160 and a portion of the post 196, with the end latch 162 illustrated in the latched state and connected to the post 196. The second end 168 of the end bar 160 is attached to another of the post 196 in a similar manner and will not be described in detail.

[0061] When the end latch 162 is in the retracted position, the latch arms 170 are located between the two flanges 184, the span 186 and the retainer 188. This creates a first box 202 around the end latch 162 that protects the end latch 162 from damage. Additionally, in normal operation, the end latch 162 is kept in the retracted position until the first end 166 is in the initial position relative to the post 196. The end latch 162 is then moved to the extend position and the latch arms extend into the hook hole 200 on the post 196, wherein a post body 204 creates a second box 206 that protects the end latch 162 from damage. As a result, the end latch 162 is protected from damage from outside impacts.

[0062] Referring to Fig. 24, there is illustrated an enlarged perspective view of a portion of a post 208 that is similar to the previously described post 20, but the post 208 includes stabilizers 210. The illustrated stabilizers 210 are metal protrusions on the post 208. However, the stabilizers 210 may be made of any desired material and by any desired method. Fig. 24 shows an end bar mount 212 with three stabilizers 210 positioned around the end bar mount 212.Fig. 25 is a side view of the post 208, with an end bar 214 shown in an installed position relative to the post 208. As shown, the stabilizers 210 are located near to the end bar 214 but not in contact with the end bar 214. Fig. 26 is a side view of a side bar 216 shown in an installed position relative to the post 208. As shown, additional stabilizers 210 are located in contact with the side bar 216. In each configuration illustrated in Figs. 25 and 26, the stabilizers 210 are adapted to engage the end bar 214 if the end bar 214 is twisted relative to the post 208. The stabilizers 210 limit movement of the end bar 214 relative to the post 208.

[0063] A number of examples have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following clauses.

[0064] Clause 1. A shipping container for one or more panels comprising: a pallet comprising a pallet body with a storage surface and a plurality of post mounts, each of the post mounts including a secondary end bar mount; a plurality of posts, each of the plurality of posts including at least one end bar mount and at least one side bar mount; a plurality of end bars, each end bar including an end latch at a first end and an end latch at a second end; a plurality of side bars, each side bar including a side latch at a first end and a side latch at a second end; and a support dunnage attached to the pallet body; wherein in an assembled state each one of the plurality of posts is attached to a respective one of the plurality of post mounts, each of theplurality of end bars is attached to two of the end bar mounts, each of the plurality of side bars is attached to two of the side bar posts, a storage space is defined by the storage surface, posts, end bars, and side bars, and the support dunnage is located in the storage space: and wherein in a stowed state each of the plurality of end bars is attached to two of the secondary end bar mounts, a stowage space is defined by the storage surface and end bars, and the support dunnage is located in the stowage space.

[0065] Clause 2. The shipping container of clause 1, wherein the support dunnage is movable relative to the pallet body between a storage position and a stowed position.Clause 3. The shipping container of clause 1, wherein the support dunnage is rotationally movable relative to the pallet body between a storage position and a stowed position.

[0066] Clause 4. The shipping container of any of the previous clauses, wherein the support dunnage in the stowed position also defines the stowage space.

[0067] Clause 5. The shipping container of any of the previous clauses, wherein the support dunnage includes a plurality of first cradles that are a first distance from the storage surface when the support dunnage is in the storage position, and a plurality of second cradles that are a second distance from the storage surface when the support dunnage is in the storage position, wherein the second distance is larger than the first distance.

[0068] Clause 6. The shipping container of any of the previous clauses, wherein the pallet body includes a seat surface that is opposite the storage surface, and each of the plurality of post mounts includes a respective lower seat that is located on a side of the post mount facing the seat surface and is spaced apart from the seat surface towards the storage surface.

[0069] Clause 7. The shipping container of clauses 1-5, wherein the pallet body includes a seat surface that is opposite the storage surface, and each of the plurality of post mounts includes a respective lower seat that is located on a side of the post mount facing the seat surface, and wherein each of the plurality of posts includes an alignment pin that is adapted to fit in one of the lower seats.

[0070] Clause 8. The shipping container of any of the previous clauses, wherein the first end latch includes a hook that engages the end bar mount and that is movable relative to the first end between an extended position and a retracted position.

[0071] Clause 9. The shipping container of clause 8, wherein the first end latch includes a pin that engages the end bar mount and that is movable relative to the first end between an extended position and a retracted position.

[0072] Clause 10. The shipping container of clause 9, wherein the first end latch includes a spring that biases the pin to the extended position.

[0073] Clause 11. The shipping container of clauses 8-10, wherein the end bar includes two flanges that are connected by a span, and a cover that is connected to each of the flanges, wherein the hook is located partially between the two flanges and partially between the span and the cover.

[0074] Clause 12. The shipping container of clause 11, wherein in the retracted position the hook is located in a first box between the two flanges, and wherein in the extended position the hook is located partially outside the first box.

[0075] Clause 13. The shipping container of clause 8, wherein the first end latch includes two latch arms that are attached to each other for relative rotational movement and a spring that biases each of the latch arms in a respective outward direction.

[0076] Clause 14. The shipping container of clause 13, wherein the end bar includes two flanges that each include a hole, the flanges are connected by a span, and the flanges are connected by a cover, wherein the hook is located partially between the two flanges and partially between the span and the cover, wherein each of the latch arms includes a stop that extends through a respective one of the holes.

[0077] Clause 15. The shipping container of clause 14, wherein in the retracted position the hook is located in a first box between the two flanges, and wherein in the extended position the hook is located partially outside the first box.

[0078] Clause 16. A shipping container for one or more panels comprising: a pallet comprising a plurality of post mounts: a plurality of posts, each supported by one of the plurality of post mounts and extending in storage direction; and a end bar including an end bar body including two flanges that are connected by a span, and an end latch, the end latch including a hook that is movable relative to the end bar body between a retracted position and an extended position, wherein the hook is located in a first box defined by the span and the flanges when the hook is in the retraced position, wherein the hook engages an end mount on one of the plurality of posts to retain the end bar in position relative to the post when the hook is in the extendedposition, wherein the hook is located in a second box defined by a post body when the hook is in the extend position.

[0079] Clause 17. The shipping container for one or more panels of clause 16, wherein the end latch includes a pin that engages the post to retain the end bar body in position relative to the post.

[0080] Clause 18. The shipping container for one or more panels of clause 16. wherein the end bar includes a second end latch with a second hook, wherein the second hook engages an end mount on a second of the plurality of posts to retain the end bar in position relative to the second post when the second hook is in an extended position.

[0081] Clause 19. The shipping container for one or more panels of clause 16, wherein the post mounts include respective secondary end bar mounts, and the hook engages the secondary end bar mount on one of post mounts to retain the end bar in a stowed position relative to the post mount when the hook is in the extended position.

[0082] Clause 20. The shipping container for one or more panels of clause 19, wherein the end bar includes a second end latch with a second hook, wherein the second hook engages the secondary end bar mount on a second of the post mounts to retain the end bar in the stowed position relative to the second post mount when the second hook is in an extended position.

Claims

64931-US-PSP / PO25O6CLAIMSWhat is claimed is:

1. A shipping container for one or more panels comprising:a pallet comprising a pallet body with a storage surface and a plurality of post mounts, each of the post mounts including a secondary end bar mount;a plurality of posts, each of the plurality of posts including at least one end bar mount and at least one side bar mount;a plurality of end bars, each end bar including an end latch at a first end and an end latch at a second end;a plurality of side bars, each side bar including a side latch at a first end and a side latch at a second end; anda support dunnage attached to the pallet body;wherein in an assembled state each one of the plurality of posts is attached to a respective one of the plurality of post mounts, each of the plurality of end bars is attached to two of the end bar mounts, each of the plurality of side bars is attached to two of the side bar posts, a storage space is defined by the storage surface, posts, end bars, and side bars, and the support dunnage is located in the storage space; andwherein in a stowed state each of the plurality of end bars is attached to two of the secondary end bar mounts, a stowage space is defined by the storage surface and end bars, and the support dunnage is located in the stowage space.

2. The shipping container of claim 1, wherein the support dunnage is movable relative to the pallet body between a storage position and a stowed position.

3. The shipping container of claim 1, wherein the support dunnage is rotationally movable relative to the pallet body between a storage position and a stowed position.

4. The shipping container of any of the previous claims, wherein the support dunnage in the stowed position also defines the stowage space.

5. The shipping container of any of the previous claims, wherein the support dunnage includes a plurality of first cradles that are a first distance from the storage surface when the support dunnage is in the storage position, and a plurality of second cradles that are a second distance from the storage surface when the support dunnage is in the storage position, wherein the second distance is larger than the first distance.

6. The shipping container of any of the previous claims, wherein the pallet body includes a seat surface that is opposite the storage surface, and each of the plurality of post mounts includes a respective lower seat that is located on a side of the post mount facing the seat surface and is spaced apart from the seat surface towards the storage surface.

7. The shipping container of claims 1-5, wherein the pallet body includes a seat surface that is opposite the storage surface, and each of the plurality of post mounts includes a respective lower seat that is located on a side of the post mount facing the seat surface, and wherein each of the plurality of posts includes an alignment pin that is adapted to fit in one of the lower seats.

8. The shipping container of any of the previous claims, wherein the first end latch includes a hook that engages the end bar mount and that is movable relative to the first end between an extended position and a retracted position.

9. The shipping container of claim 8, wherein the first end latch includes a pin that engages the end bar mount and that is movable relative to the first end between an extended position and a retracted position.

10. The shipping container of claim 9, wherein the first end latch includes a spring that biases the pin to the extended position.

11. The shipping container of claims 8-10, wherein the end bar includes two flanges that are connected by a span, and a cover that is connected to each of the flanges, wherein the hook is located partially between the two flanges and partially between the span and the cover.

12. The shipping container of claim 11, wherein in the retracted position the hook is located in a first box between the two flanges, and wherein in the extended position the hook is located partially outside the first box.

13. The shipping container of claim 8, wherein the first end latch includes two latch arms that are attached to each other for relative rotational movement and a spring that biases each of the latch arms in a respective outward direction.

14. The shipping container of claim 13, wherein the end bar includes two flanges that each include a hole, the flanges are connected by a span, and the flanges are connected by a cover, wherein the hook is located partially between the two flanges and partially between the span and the cover, wherein each of the latch arms includes a stop that extends through a respective one of the holes.

15. The shipping container of claim 14, wherein in the retracted position the hook is located in a first box between the two flanges, and wherein in the extended position the hook is located partially outside the first box.

16. A shipping container for one or more panels comprising:a pallet comprising a plurality of post mounts;a plurality of posts, each supported by one of the plurality of post mounts and extending in storage direction; anda end bar including an end bar body including two flanges that are connected by a span, and an end latch, the end latch including a hook that is movable relative to the end bar body between a retracted position and an extended position, wherein the hook is located in a first box defined by the span and the flanges when the hook is in the retraced position, wherein the hook engages an end mount on one of the plurality of posts to retain the end bar in position relative to the post when the hook is in the extended position, wherein the hook is located in a second box defined by a post body when the hook is in the extend position.

17. The shipping container for one or more panels of claim 16, wherein the end latch includes a pin that engages the post to retain the end bar body in position relative to the post.

18. The shipping container for one or more panels of claim 16, wherein the end bar includes a second end latch with a second hook, wherein the second hook engages an end mount on a second of the plurality of posts to retain the end bar in position relative to the second post when the second hook is in an extended position.

19. The shipping container for one or more panels of claim 16, wherein the post mounts include respective secondary end bar mounts, and the hook engages the secondary end bar mount on one of post mounts to retain the end bar in a stowed position relative to the post mount when the hook is in the extended position.

20. The shipping container for one or more panels of claim 19, wherein the end bar includes a second end latch with a second hook, wherein the second hook engages the secondaryend bar mount on a second of the post mounts to retain the end bar in the stowed position relative to the second post mount when the second hook is in an extended position.

Images