ARMORED CRATE APPARATUS AND MANUFACTURING SYSTEM

Abstract

An armored enclosure apparatus and system of manufacturing thereof is described. The apparatus is equipped with an enclosure substrate, at least one opening panel, and a durable exterior coating. The exterior coating is preferably molded to the exterior of the enclosure substrate, resulting in a fortified container suitable for storage, transport, and delivery of sensitive, fragile, valuable, and otherwise damage-prone items. An interior of the enclosure substrate may also be equipped with a molded coating configured to further protect contents of the enclosure. Thickness of the exterior coating may vary in accordance with the size of the enclosure, and the contents.

Description

[0001] This application is a non-provisional application of provisional patent application number 62/656,659, filed on Apr. 12, 2018, and priority is claimed thereto.

FIELD OF THE PRESENT INVENTION

[0002] The present invention relates to the field of shipping, material handling, protection, and logistics, and more specifically relates to an armored enclosure apparatus, and manufacturing system thereof, which facilitates safe transport and storage of fragile and/or expensive items such as sensitive electronics, luxury furniture, valuable minerals/gems, moisture-sensitive items, any delicate goods, etc.

BACKGROUND OF THE PRESENT INVENTION

[0003] There are several different means by which items may be transported via air or ground freight. While many conventional items are adequately transported in cardboard or similarly structured disposable boxes, it is inevitable that the contents of some boxes will be damaged. Damage often occurs during transit, as well as within a storage warehouse while awaiting shipment. Packaged products can be damaged if they are impacted from a forklift, from a warehouse storage rack, or can even be damaged during loading to a truck. Likewise, contents of crates and boxes can be damaged during delivery, as they may be impacted while within the storage bay of a delivery truck upon taking a sharp turn. In some cases, traditional packaging and their respective contents may be destroyed upon falling from the truck or forklift, or from the hands of delivery personnel. This is especially true for packages containing sensitive items, such as computer servers, luxury furniture, sensitive vehicle components, photography equipment, other volatile electronics, or any delicate products.

[0004] If there were a way by which such items could be more sufficiently protected during storage, transit, and delivery, damaged merchandise and prized possessions would be far less susceptible to irreparable damage.

[0005] Some solutions to instances of property damage during transit presently exist on the market. For example, Pelican.TM. (and similar companies) manufactures durable, fortified plastic and/or metal containers suitable for specific valuable items, such as firearms, photography equipment, precious minerals, and other delicate items. While effective, containers such as these are prohibitively expensive, and are generally designed for a singular purpose--the transport of a specific item, encased within an internal form-fitting foam of the container. This foam is usually custom-sized for the contents of the container, adding to the expense. Additionally, containers such as these are generally purchased and used by the owner of the item, and are therefore purchased after the owner is in possession of the fragile item. In accordance with their high cost, containers such as these are often equipped with a lifetime warranty, and are designed to be used hundreds of times without failing.

[0006] However, containers such as these are not suitable for the conventional transport of fragile/sensitive goods. Unfortunately, the fact remains that simple foam inserts of cardboard boxes, in addition to bubble wrap (or similar air-based filler material) and/or packing peanuts, remain the most commonly used (and most cost effective) means by which fragile items are transported. These protective elements often fail.

[0007] Thus, there is a need for a new form of armored shipping apparatus suitable for use by both individuals and corporations, to more safely transport valuable, sensitive, and otherwise fragile goods in a cost effective manner. Such an apparatus preferably employs a crate, which is then coated in a durable, shock absorbing, semi-elastic compound, which effectively protects the substrate (lending to improved protection and re-use of the crate) as well as its contents during storage, loading, transit, and delivery.

SUMMARY OF THE PRESENT INVENTION

[0008] This Summary of the Invention is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0009] The present invention is an armored enclosure and process of manufacturing thereof, which is configured to protect contents from damage during storage and transit, as well as prevent contamination of the contents by infestation, liquids, corrosives, and other conventional contaminants. The armor of the armored crate is an exterior coating preferably composed of Polyurea or Polyurethane (or a blend). The exterior coating is applied as at least one layer of protection, and is configured to both seal the substrate from contaminants, as well as to provide shock absorption, increasing the structural integrity of enclosure. The present invention is preferably equipped with at least one opening panel which is configured to be removed by the end user to retrieve the protected contents of the apparatus.

[0010] Some embodiments of the present invention are equipped with an interior coating similar to that of the exterior coating. The interior coating, in addition to the exterior coating, provides additional protection of the contents during storage, transport, and delivery.

[0011] It is envisioned that the enclosure substrate of the present invention is preferably composed of one or more of the following components: bamboo, hemp, cellular PVC, plastic, vinyl, straw composite, paper, metal, fiberboard, fiberglass, fiberglass-faced gypsum panels, corrugated plastic, corrugated cardboard, carbon fiber, mesh, or composites. Exterior coating of the present invention is present at a thickness ranging from 0.015 inches to two inches in order to adequately increase the structural integrity of the enclosure assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

[0013] The present invention will be better understood with reference to the appended drawing sheets, wherein:

[0014] FIG. 1 depicts an environmental view of the preferred embodiment of the apparatus of the present invention as seen from the front and side.

[0015] FIG. 2 exhibits a front and side view of the raw substrate of the apparatus of the present invention.

[0016] FIG. 3 shows a cutaway view of the apparatus of the present invention, showing a portion of the enclosure as raw substrate, and a portion of the enclosure equipped with coating.

[0017] FIG. 4 depicts an environmental view of the apparatus of the present invention, showing the opening panel in the open position, and equipped with contents.

[0018] FIG. 5 shows a cross-sectional view of the exterior coating layer of the present invention, depicted atop the enclosure substrate.

[0019] FIG. 6 exhibits a flow chart detailing the manufacturing process of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] The present specification discloses one or more embodiments that incorporate the features of the invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s). The invention is defined by the claims appended hereto.

[0021] References in the specification to "one embodiment," "an embodiment," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment, Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0022] The present invention is an armored enclosure (20) apparatus suitable for use during the transport and storage of fragile or otherwise sensitive goods. The apparatus amounts to an enclosure for storing goods to protect them from theft, leakage, exposure, and damage due to natural or physical forces and contamination.

[0023] The apparatus of the present invention is equipped with an enclosure substrate (40), which is preferably composed of hemp, straw composite, bamboo, cellular PVC, metal, fiberglass, fiberglass-faced gypsum panels, corrugated plastic, corrugated cardboard, carbon fiber, mesh, or similar sturdy planar material. The enclosure substrate (40) is fashioned into panels of varying thickness, which is assembled as an enclosure equipped with an interior (50). The interior (50) may be equipped with, or without dividers, amounting to a perimeter shell as shown in FIG. 2 and FIG. 3. Foam may also be used as the enclosure substrate (40).

[0024] Additionally, one or more sides of the enclosure substrate (40) is an opening panel (30), which is preferably removable in order to deposit or retrieve contents (60) housed within the apparatus of the present invention. The opening panel (30) may be removed via prying, or may be configured to pivot, slide, or retract to act as a hinged or sliding door.

[0025] The exterior of the enclosure substrate (40) is equipped with an exterior coating (10), the coating is preferably composed of a layer(s) of Polyurea or Polyurethane (or a blend). The exterior coating (10) is preferably present at a thickness of 0.015 to two inches in order to increase the structural integrity of the enclosure substrate (40). The exterior coating (10) of the present invention is configured to allow more volatile and/or fragile goods to be stored within the present invention. The exterior coating (10) is therefore a non-corrosive, liquid-proof contamination barrier.

[0026] Similarly, an interior (50) of the present invention may also be equipped with an interior coating (70). The interior coating (70) preferably has a thickness between 0.015 inches and two inches, and is present in order to further increase the structural integrity of the enclosure substrate (40). In such instances, the present invention may be used to transport even more volatile goods, including liquids, and adds a non-corrosive, infestation-proofing, and contaminate-proofing barrier internally. The interior coating (70) employed in some embodiments of the present invention may also be food-safe to facilitate transport of fragile food items.

[0027] The process by which the apparatus of the present invention is preferably constructed, as depicted in FIG. 6, is preferably as follows:

[0028] 1. First, a conventional fortified crate is manufactured with at least one panel of the conventional six panels configured to pivot or be removed to facilitate depositing or retrieval of stored goods. The removable or pivoting opening panel is temporarily closed. (100) In embodiments of the present invention equipped with an interior coating, the interior coating is first applied to the entire assembly or individual panels composing the enclosure.

[0029] 2. Next, with the enclosure closed but without the opening panel attached, at least one layer (though preferably several) of Polyurea or Polyurethane (or a blend of the two) is applied to the exterior of the enclosure substrate, forming a cohesive barrier surrounding all components of the exterior of the enclosure substrate. (110) The layer(s) are preferably applied via a spray or molding process by which the Polyurea or Polyurethane is chemically bonded to the enclosure substrate (regardless of the material composition of the enclosure substrate).

[0030] 3. Then, after the Polyurea or Polyurethane has dried and hardened, the armored enclosure may accept hardware items followed by contents for storage and transport. (120)

[0031] 4. Finally, after the armored enclosure is equipped with content (goods), the opening panel(s) are secured, and the armored enclosure is sealed (with or without a watertight gasket) until it reaches the end consumer at a final destination. (130)

[0032] Additionally, some embodiments of the present invention may be equipped with one or more mechanical fasteners, such as a bolt action fastener, screws, at least one clasp, lever, and/or similar security device (such as a padlock, keyed lock, or electrical lock) to ensure that the at least one opening panel (30) remains in position securely during storage and transport.

[0033] It should be understood that the armored enclosure (20) of the present invention may be one of an assortment of infinitely ranging sizes configured to store sizable goods, some of which requiring material handling equipment such as forklifts, pallet jacks, lift gates, and/or overhead lifting device. The size of the enclosure substrate need not limit the scope of the present invention.

[0034] Having illustrated the present invention, it should be understood that various adjustments and versions might be implemented without venturing away from the essence of the present invention. Further, it should be understood that the present invention is not solely limited to the invention as described in the embodiments above, but further comprises any and all embodiments within the scope of this application.

[0035] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.

Claims

1. An armored crate apparatus comprising: an enclosure; an enclosure substrate, said enclosure substrate composed of at least one of the following: hemp, straw composite, bamboo, cellular PVC, metal, fiberglass, fiberglass-faced gypsum panels, corrugated plastic, corrugated cardboard, carbon fiber, and mesh; wherein said enclosure encompasses said enclosure substrate; an interior, said interior present within said enclosure substrate; an opening panel, said opening panel disposed as one of multiple panels of said enclosure; and an exterior coating, said exterior coating disposed atop said enclosure substrate.

2. The apparatus of claim 1, wherein said exterior coating is composed of at least one layer of polyurethane.

3. The apparatus of claim 1, wherein said exterior coating is non-corrosive.

4. The apparatus of claim 1, wherein said exterior coating is a liquid-proof contamination barrier.

5. The apparatus of claim 1, further comprising: an interior coating, said interior coating disposed within said interior, on an underside of said enclosure substrate.

6. The apparatus of claim 5, wherein said interior coating is food-safe.

7. The apparatus of claim 5, wherein said interior coating is an infestation-proofing barrier.

8. The apparatus of claim 5, wherein said interior coating is a contaminate-proofing barrier.

9. The apparatus of claim 1, wherein said opening panel is configured to pivot up and away from said enclosure, facilitating access to said interior.

10. The apparatus of claim 1, wherein said opening panel is configured to be pried off of said enclosure to facilitate access to said interior.

11. The apparatus of claim 1, wherein said exterior coating is composed of at least one layer of polyurea.

12. The apparatus of claim 5, wherein said exterior coating is composed of at least one layer of polyurethane.

13. The apparatus of claim 5, wherein said exterior coating is composed of at least one layer of polyurea.

14. The apparatus of claim 5, wherein said exterior coating is a liquid-proof contamination barrier.

15. The apparatus of claim 5, wherein said opening panel is configured to pivot away from said enclosure, facilitating access to said interior.

16. The apparatus of claim 5, wherein said opening panel is configured to be pried off of said enclosure to facilitate access to said interior.

17. An armored crate apparatus comprising: an enclosure; an enclosure substrate, said enclosure substrate composed of at least one of the following: hemp, straw composite, bamboo, cellular PVC, metal, fiberglass, fiberglass-faced gypsum panels, corrugated plastic, corrugated cardboard, carbon fiber, and composite; wherein said enclosure encompasses said enclosure substrate; an interior, said interior present within said enclosure substrate; an opening panel, said opening panel disposed as one of multiple panels of said enclosure; and an exterior coating, said exterior coating disposed atop said enclosure substrate.