Container for use with and method of managing an overhead track chain

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority is claimed to U.S. provisional patent application Ser. No. 60/376,584 filed on Apr. 30, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a container. In one aspect, the invention relates to a container for managing an overhead track chain.

2. Description of the Related Art

In conventional assembly line manufacturing, conveyor systems are often used to shuttle materials from a source to and through one or more workstations. These conveyor systems typically rely on one or more bulky chains, such as overhead track chains, to convey the requisite materials. The overhead track chains (i.e., universal link chains), which are out-fitted with and utilize “pusher dogs” and “trolleys”, engage with, transport, and then disengage from the materials. As such, the materials can be carried through the assembly line by the overhead track chains where a variety of tasks can be performed on the materials at the workstations.

Unfortunately, the packaging, transporting, storing, and managing of the overhead track chains which are used in the conveyor systems can be extremely problematic. The overhead track chains are often very large and very heavy. Also, the chains are constructed of links that permit and encourage the chain to swivel or otherwise move at or between the links. This can cause difficulties, for example, when a manufacturer of the chains attempts to package the chains within conventional packaging and shipping containers, when the chains are removed from conveyor systems by technicians for maintenance, repair, replacement, installation and/or reconfiguration, and the like.

At present, manufacturers and users of overhead track chains employ a specially configured container with a “double box” design for packaging, shipping, transporting, and storing the chains. These double box containers use styrofoam spacers, which are disposed in corners and the center of the container, to secure and balance the chain that has been stowed therein.

Undesirably, the styrofoam spacers have a tendency to deteriorate over time. As a result, the overhead track chain packaged in the container shifts and/or slides when the container is moved. Therefore, the container is unstable and difficult for workers to carry and otherwise difficult to handle. Additionally, when the styrofoam spacers break apart, pieces or fragments of the styrofoam can become lodged in and around the overhead track chain stored in the container. If the styrofoam pieces are not adequately cleaned from the overhead track chain, various problems can arise. For example, the chain can fail prematurely during later use in the conveyor system.

Overhead track chains are also, at times, transported and shipped by manufacturers and users inside containers such as conventional buckets, pails, and the like. These buckets have a vacant and/or hollow interior, defined by a periphery of the bucket, which is devoid of any support feature. In other words, the periphery of the bucket is the only boundary restricting movement of the chain when the chain is disposed in the hollow interior. No structure or apparatus is provided within the hollow interior to guide, manage, and/or steadfastly secure the chain. Therefore, when the chain is disposed and/or placed within the bucket for transportation and/or shipping, the container is unable to adequately control the movements, sway, and shifting of the chain stored therein.

Thus, a container for use with, and for managing, an overhead track chain would be desirable. Likewise, a method of stowing an overhead track chain in the container would also be desirable.

SUMMARY OF THE INVENTION

In one aspect, the invention provides a container for use with an overhead track chain. The container comprises a base, which includes a spool, and a housing that is securable to the base. The spool extends from the base and is structured to progressively guide the overhead track chain around the spool in a winding fashion. The housing surrounds at least a portion of the spool such that an overhead track chain storage area is formed. The overhead track chain is guided around the spool in the winding fashion and received within the overhead track chain storage area.

In another aspect, the invention provides a container for managing an overhead track chain. The container comprises a base defining a top surface, a tapered spool defining an interior, and a cylindrical housing. The tapered spool is disposed upon, and extends diminishingly away from, the top surface of the base, has an accessory storage area disposed within the interior of the tapered spool, and is structured to progressively guide the overhead track chain around the tapered spool in a winding fashion. The cylindrical housing is securable to the top surface of the base and surrounds at least a portion of the tapered spool such that an overhead track chain storage area is formed. The overhead track chain is guided around the tapered spool in a winding fashion and received within the overhead track chain storage area.

In a further aspect, the invention provides a method of stowing an overhead track chain. The method comprises providing the overhead track chain and providing a container for managing the overhead track chain. The container includes a base having a tapered spool and a housing securable to the base. The tapered spool extends from the base and is structured to progressively guide the overhead track chain around the tapered spool in a winding fashion. The housing surrounds at least a portion of the tapered spool such that an overhead track chain storage area is formed. A vertically-oriented overhead track chain is introduced into the overhead track chain storage area within the container and the vertically-oriented overhead track chain is wound around the tapered spool in the overhead track chain storage area of the container until the overhead track chain is at least substantially entirely received within the overhead track chain storage area. Thus, the overhead track chain is stowed.

In yet another aspect, the invention provides a container in combination with an overhead track chain. The container comprises a base having a tapered spool and a housing securable to the base. The tapered spool extends from the base and is structured to progressively guide the overhead track chain around the tapered spool in a winding fashion. The housing surrounds at least a portion of the tapered spool such that an overhead track chain storage area is formed. The overhead track chain comprises a load-carrying link and a lateral guide link. Each of the load-carrying link and the lateral guide link has a universal pin and a universal pin aperture such that the load-carrying link and the lateral guide link are pivotable with respect to each other. The pivotable load-carrying link and the lateral guide link permit the overhead track chain to be guided around the tapered spool in the winding fashion and be received within the overhead track chain storage area. As such, the overhead track chain is at least substantially entirely disposed within the container.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in its application to the details of construction, or the arrangement of the components, illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components.

FIG. 1

illustrates a side view of a typical conveyor system capable of employing an overhead track chain.

FIG. 2

illustrates a side view of a pusher dog used in the conveyor system of FIG.

1

.

FIG. 3

illustrates a side view of a trolley used in the conveyor system of FIG.

1

.

FIG. 4

illustrates a perspective view of the overhead track chain used in the conveyor system of FIG.

1

.

FIG. 5

illustrates a side view of the overhead track chain of FIG.

4

.

FIG. 6

illustrates a perspective view of one embodiment of a container for storing the overhead track chain of

FIG. 4

in accordance with one aspect of the present invention.

FIG. 7

illustrates a perspective view of a base, which includes a spool, of the container of

FIG. 6

according to one aspect of the present invention.

FIG. 8

illustrates a perspective view of a housing of the container of

FIG. 6

according to one aspect of the present invention.

FIG. 9

illustrates a cross-sectional view, taken along line

9

—

9

, of another embodiment of the container of

FIG. 6

when the container has a unitary construction in accordance with another aspect of the present invention.

FIG. 10

illustrates the container of

FIG. 6

including a lid and a handle according to one aspect of the present invention.

FIG. 11

illustrates the container of

FIG. 6

having a partially cut-away housing highlighting the spool.

FIG. 12

illustrates a flow diagram that outlines a method for stowing the overhead track chain of

FIG. 4

in the container of

FIG. 6

according to one aspect of the present invention.

FIGS. 13A-B

illustrate the container of

FIG. 6

having a partially cut-away housing and receiving the overhead track chain of

FIG. 4

in a winding fashion according to one aspect of the present invention.

FIG. 14

illustrates the container of

FIG. 6

having a partially cut-away housing when the overhead track chain of

FIG. 4

is stowed in the container according to one aspect of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to

FIG. 1

, conveyor system

10

is illustrated transporting materials

12

. Materials

12

can include parts, components, products, and the like that are ferried from place to place during typical assembly line manufacturing. Conveyor system

10

generally includes one or more Tracks

14

a

and

14

b

(collectively

14

), one or more pusher dogs

16

, one or more trolleys

18

, and an overhead track chain

20

(i.e., a universal link chain). Overhead track chain

20

is often driven and/or pulled through track

14

a

in a conveyor system

10

such as, for example, track

14

a

which is positioned vertically above track

14

b

. In preferred embodiments, track

14

a

is an “enclosed” track and track

14

b

is either an “enclosed” track or an “open” track. In those embodiments where track

14

b

is an “open” track, the track is typically an I-beam track.

As shown in

FIG. 1

, a portion of each track

14

is cut-away or removed to more clearly illustrate components (e.g., overhead track chain

20

, etc.) of conveyor system

10

. Tracks

14

are structured to receive one or more pusher dogs

16

, one or more trolleys

18

, and overhead track chain

20

. As such, pusher dogs

16

, trolleys

18

, and overhead track chain

20

are permitted to ride upon and/or through one of tracks

14

. Tracks

14

are typically manufactured in, for example, either straight or curved sections (not shown) of about twenty feet in length. These sections are welded or otherwise secured together to permit tracks

14

to be as long or short, and as straight or meandering, as desired by a user of conveyor system

10

. Since tracks

14

must ultimately support a considerable amount of weight (e.g., from materials

12

, from various conveyor components, etc.) the Tracks are often constructed of, for example, high carbon steel.

Pusher dogs

16

, as shown in

FIGS. 1 and 2

, comprise pusher dog wheels

22

and catch

24

. Pusher dog wheels

22

are structured to permit pusher dog

16

to travel in and through track

14

a

. Preferably, pusher dog wheels

22

rotate freely and are formed such that the pusher dogs can glide smoothly through track

14

a

. Catch

24

on pusher dog

16

is structured to permit the pusher dog to engage with one of trolleys

18

.

As shown in

FIG. 3

, trolley

18

comprises trolley wheels

26

, means

28

for securing materials, and receiver

30

. Trolley wheels

26

are structured to permit trolley

18

to travel on or through track

14

b

. Preferably, trolley wheels

26

rotate freely and are formed such that the trolleys can glide smoothly on or through track

14

b

. Means

28

for securing materials is structured to permit each trolley

18

to suspend and carry materials

12

from a source (not shown) to a workstation (not shown) or from one workstation to another. Receiver

30

is structured to permit trolley

18

to engage with catch

24

disposed on one of pusher dogs

16

.

In preferred embodiments as shown in

FIGS. 4 and 5

, overhead track chain

20

is produced by combining and/or securing together one or more load-carrying links

32

and/or lateral guide links

34

. Preferably, a plurality or series of links

32

,

34

are included in overhead track chain

20

. Although permitted to be coupled together in a variety of sequences, load-carrying links

32

and lateral guide links

34

are preferably ordered such that the load-carrying links and the lateral guide links alternate in some fashion. For example, one or more load-carrying links

32

follow one or more lateral guide links

34

, which are followed by additional load-carrying lengths, and so on and so forth. Each load-carrying link

32

and lateral guide link

34

includes one or more chain wheels

36

, a plurality of universal pins

38

, and a plurality of universal pin apertures

40

.

In general, chain wheels

36

disposed on load-carrying links

32

accommodate vertically-applied loads while the chain wheels disposed on lateral guide links

34

manage laterally-applied loads. Since, for example, vertically-applied loads upon load-carrying links

32

are often substantial, multiple chain wheels

36

can be used in combination or together to bear the heavy load. Preferably, chain wheels

36

on each of load-carrying links

32

and lateral guide links

34

rotate freely and are formed such that the links can glide smoothly on or through one of Tracks

14

. Chain wheels

36

can be constructed of steel, other metals, nylon, and the like.

Universal pins

38

and universal pin apertures

40

are found on both load-carrying links

32

and lateral guide links

34

. Universal pins

38

and universal pin apertures

40

are selectively engageable such that load-carrying links

32

and lateral guide links

34

can be secured to one another. Likewise, several load-carrying links

32

can be secured other load-carrying links and several lateral guide links

34

can be secured to other lateral guide links. Therefore, when universal pins

38

and universal pin apertures

40

engage each other, links

32

,

34

are connected and/or secured together such that overhead track chain

20

is produced.

Any number of load-carrying links

32

and lateral guide links

34

can be joined together to form overhead track chain

20

. As links

32

,

34

are added, overhead track chain

20

grows larger and larger in length. In contrast, as links

32

,

34

are removed, overhead track chain

20

shrinks in length.

Since links

32

,

34

are connected and/or secured by engagement of universal pins

38

and universal pin apertures

40

, the links are permitted to swivel, pivot, and/or twist. Correspondingly, overhead track chain

20

can swivel, pivot, and/or twist.

Referring again to

FIG. 1

, one or more pusher dogs

16

are inserted or incorporated into overhead track chain

20

(

FIG. 4

) between links

32

,

34

when the overhead track chain is used in conveyor system

10

. Pusher dogs

16

can include universal pin apertures (not shown) that are compatible with universal pins

38

(

FIG. 4

) disposed on load-carrying links

32

and lateral guide links

34

. When inserted into overhead track chain

20

, pusher dogs

16

typically separate lateral guide links

34

. In other words, pusher dogs

16

become a part or portion of overhead track chain

20

when the overhead track chain is used in conveyor system

10

.

As overhead track chain

20

is driven and/or moves within and through track

14

a

, pusher dogs

16

that have been added to the chain engage with receivers

30

on trolleys

18

while the trolleys are securing materials

12

with means

28

for securing materials. Engagement of pusher dogs

16

and trolleys

18

causes the trolley to move on or through Tracks

14

b

. As overhead track chain

20

progresses through conveyor system

10

, materials

12

held by trolleys

18

likewise and resultantly progress through the conveyor system. Therefore, overhead chain

20

rolls and “snakes” through track

14

a

, the chain uses pusher dogs

16

to pull trolleys

18

(including materials

12

) on or through track

14

b

until the pusher dogs and the trolleys disengage. Thus, materials

12

are transported as desired by conveyor system

10

.

While overhead track chain

20

performs well within conveyor system

10

, the overhead track chain can be problematic prior to insertion into, or after removal from, the conveyor system. Simply put, overhead track chain

20

is difficult to package, transport, store, handle, maneuver, and otherwise manage (collectively “manage”) when independent of conveyor system

10

since the chain is bulky, heavy, and can, if not constrained, swivel between engaged links

32

,

34

.

When outside of or apart from conveyor system

10

, overhead track chain generally comprises only load-carrying links

32

and lateral guide links

34

as shown in FIG.

4

. These load-carrying links

32

and lateral guide links

34

(including chain wheels

36

) are often constructed of a high-strength metal (e.g., a drop-forged, high-strength steel) or other heavy, strong, and/or dense materials. Therefore, overhead track chain

20

is often extremely heavy. As more and more links

32

,

34

are added to overhead track chain

20

, the chain becomes increasingly bulky and heavy. Also, since links

32

,

34

are commonly joined together by universal pins

38

and universal pin apertures

40

, which permit swiveling, overhead track chain

20

is pivotable. In other words, overhead track chain can be cumbersome to manage and/or maneuver.

Referring to

FIG. 6

, container

42

for use with and for managing bulky chains (e.g., overhead track chains

20

as shown in

FIGS. 4 and 5

) is illustrated. When overhead track chains

20

are disposed within container

42

, the container is capable of protecting these bulky chains from objects impacting the chains as well as from debris, moisture, and other contaminants. Such objects and contaminants can have adverse and/or deleterious effects upon overhead track chains

20

. As shown in

FIGS. 7 and 8

, container

42

generally comprises base

44

and housing

46

, respectively.

Referring to

FIG. 7

, base

44

includes spool

48

and defines top surface

50

. Spool

48

is disposed upon, and extends diminishingly away from, top surface

50

of base

44

. In other words, a periphery

52

(e.g., a circumference) of spool

48

gets smaller as the spool continues to extend and/or protrude farther away from top surface

50

of base

44

. Therefore, in preferred embodiments, spool

48

is constructed to be frustoconical, conical, tapered, or the like (collectively “tapered”). The “tapered” and/or “diminishing” shape and/or configuration of spool

48

permits and/or encourages the overhead track chain

20

to be progressively guided and/or received around or proximate the spool in a winding fashion. The tapered nature of spool

48

essentially permits the spool to guide (e.g., direct, shepherd, etc.) overhead track chain

20

when the chain is wound about the spool. The tapered nature of spool

48

also encourages overhead track chain

20

to be wound such that the chain is centered and/or balanced within container

42

.

As used herein, the phrases “progressively guided” and “progressively received generally signify that portions (e.g., segments) of overhead track chain

20

are deposited upon other previously-deposited portions of the chain as the chain is introduced into container

42

. In other words, spool

48

guides overhead track chain

20

such that the chain is stacked, piled, and/or heaped upon itself. Also, since the chain is guided and received in a winding fashion, overhead track chain

20

essentially encircles and/or surrounds spool

48

. In other words, as used herein, the phrase “winding fashion” generally means that overhead track chain

20

is more or less wrapped, either engagingly or proximately, around spool

48

. In other words, spool

48

guides overhead track chain

20

such that the chain encircles, besieges, and/or surrounds the spool. Receipt of overhead track chain

20

can be performed, for example, by introducing the chain into container

42

in a clockwise or counter-clockwise manner.

Since spool

48

is tapered and acts as a guide for overhead track chain

20

when the chain is progressively received around the spool in a winding fashion, container

42

can accommodate the receipt of bulky, heavy chains that can swivel if not constrained. Container

42

, and in particular spool

48

, permits links

32

,

34

in overhead track chain

42

to swivel just enough to permit the chain to be progressively guided and received in a winding fashion in container

42

. At the same time, links

32

,

34

inhibit and/or prevent overhead track chain

20

from pivoting, sagging, and otherwise becoming difficult to manage.

In one embodiment as shown in

FIG. 8

, housing

46

is cylindrical and is dimensioned to correspond to base

44

of FIG.

7

. As such, housing

46

(

FIG. 8

) is securable to top surface

50

of base

44

(

FIG. 7

) by welding, a friction fit, rivets, nuts and bolts, and the like to produce container

42

as depicted in FIG.

6

. In an alternative embodiment as shown in

FIG. 9

, container

42

can have a unitary construction. In other words, housing

46

and base

44

are simply “portions” of container

42

and the container is fashioned from a single piece of material. In other words, container

42

is essentially seamless.

Regardless of whether base

44

and housing

46

are secured together, or container

42

has a “one-piece” construction, housing

46

surrounds at least a portion of spool

48

. Therefore, as illustrated in

FIG. 9

, housing

46

, base

44

, and spool

48

together form and define overhead track chain storage area

54

. Overhead track chain storage area

54

capable of receiving overhead track chain

20

. Overhead track chain storage area

54

is likewise capable of storing and/or holding overhead track chain

20

as well.

In a preferred embodiment as shown in

FIG. 9

, spool

48

includes an interior

56

that encompasses and contains accessory storage area

58

. Accessory storage area

58

is capable of receiving one or more accessories (not shown) such as instructions for using overhead track chain

20

, lubrication materials, nuts, bolts, links for the chain, and the like. In preferred embodiments, accessory storage area

58

is produced to be frustoconical, conical, tapered, concave, cylindrical, or the like. In those cases where accessory storage area

58

is frustoconical, conical, and tapered, the tapering and/or narrowing of accessory storage area

56

generally increases as the accessory storage area extends toward top surface

50

.

Spool

48

is also preferably tapered about zero (0) to about fifteen (15) degrees and, therefore, an angle formed between periphery

52

of spool

48

and top surface

50

of base

44

is about ninety (90) to about one hundred five (105) degrees. In one exemplary embodiment, spool

48

is tapered about two (2) degrees when container

42

is dimensioned similarly to a three and a half (3½) gallon bucket as well known and conventionally used in the industry. Therefore, the angle that is formed between periphery

52

of spool

48

and top surface

50

of base

44

is about ninety-two (92) degrees. In another exemplary embodiment, spool

48

is tapered about four (4) degrees when container

42

is dimensioned similarly to a seven (7) gallon bucket as well known and conventionally used in the industry. Therefore, the angle that is formed between periphery

52

of spool

48

and top surface

50

of base

44

is about ninety-four (94) degrees.

In a further preferred embodiment as shown in

FIG. 10

, container

42

includes handle

60

for carrying the container and/or a lid

62

for sealing the container. Handle

60

makes transportation of container

42

easier, more convenient, and the like. Lid

62

, on the other hand, can afford increased protection (i.e., protection greater than that of container

42

acting alone) to overhead track chain

20

from objects that might strike and injure the chain as well as debris, moisture, and contaminants that might harm the chain.

In

FIG. 11

, a portion of housing

46

has been cut-away or removed from container

42

. Therefore, base

44

, which operates either as a part or a portion of container

42

, is more clearly illustrated. Also,

FIG. 11

also provides a perspective view and otherwise displays accessory storage area

58

in container

42

.

In the flow diagram of

FIG. 12

, a method or process

64

for stowing overhead track chain

20

in container

42

is illustrated. Process

64

begins by providing

66

overhead track chain

20

and container

20

for managing the chain. When overhead track chain

20

is provided, overhead track chain

20

is often (but not always) received

68

in a horizontal orientation as a result of having been operated in an track

14

, having been recently assembled or constructed, and the like. Therefore, at least a portion of overhead track chain

20

is maneuvered

70

from the horizontal orientation into a vertical orientation.

Once at least a portion of the overhead track chain

20

is disposed in the vertically-oriented position, the chain is introduced

72

into overhead track chain storage area

62

in container

42

. Introduction

72

of overhead track chain

20

can be performed by manually, semi-automatically, or automatically lowering vertically-oriented the overhead track chain into container

42

. As used herein, manual insertion connotes insertion without the use or aid of automated, mechanical, and similar equipment. Semi-automatic and automatic would, therefore, require the use of machines, computers and networks, robotics, and the like.

After entering overhead track chain storage area

62

, the now vertically-oriented overhead track chain

20

(or portion thereof) is wound

74

(i.e., coiled, spiraled, etc.) around tapered spool

48

in overhead track chain storage area

62

of container

42

as progressively shown in

FIGS. 13A-B

. Overhead track chain

20

preferably winds such that the chain is centered and/or balanced in overhead track chain storage area

54

in container

42

.

Winding

74

of overhead track chain

20

can be performed by permitting container

42

to rotate or by rotating the container. For example, container

42

can rotate as a result of interaction between overhead track chain

20

and tapered spool

48

. Since overhead track chain

20

is heavy, and spool

48

is tapered, the chain naturally “winds” when lowered into container

42

. Alternatively or additionally, a mechanical device (not shown) can rotate container

42

to assist or entirely perform winding

74

. Mechanical devices capable of providing rotation or a rotating force, as well as their manner of use, are well known in the art.

Winding

74

of overhead track chain

20

around tapered spool

48

continues until the chain is at least substantially entirely received within overhead track chain storage area

54

as shown in FIG.

14

. Therefore, as depicted in

FIG. 14

, overhead track chain

20

has been received in a winding fashion around spool

48

and within overhead track chain storage area

54

. Thus, overhead track chain

20

is stowed

76

(i.e., stored, packaged, etc.) in container

42

.

When overhead track chain

20

is stored in container

42

, the container can protect the overhead track chain from objects striking the chain, contaminants harming the chain, and the like. In a similar fashion, container

42

can also protect one or more accessories (not shown) when the accessories are optionally placed

78

(

FIG. 12

) and/or stored in accessory storage area

58

. Contents (e.g., overhead track chain, accessories, etc.) of container

42

can be additionally protected if the container is optionally sealed

80

with lid

60

(FIG.

12

).

To remove overhead track chain

20

from container

42

, the chain is grasped (preferably by a link

32

,

34

having a universal pin

40

that is not attached to another link) and pulled upwardly and/or away from the container. When this occurs, overhead track chain

20

unwinds and is allowed to discharge and/or be expelled from container

42

. Therefore, container

42

permits and is structured for removal of overhead track chain

20

as well as managing the chain.

In addition to compatibility with overhead track chains

20

, container

42

can be suitably employed to accommodate and receive equivalent heavy, bulky chains such as those used in power and free conveyors, continuous flow conveyors, hand-pushed conveyors, over-and-under conveyors, wide-track conveyors, enclosed track conveyors, caterpillar drive conveyors, I-beam conveyors, floor chain conveyors, chain on edge conveyors, and the like.

In preferred embodiments, base

44

, spool

48

, and housing

46

can be constructed of plastic, polypropylene, polyethylene, nylon, steel, wood, cardboard, and like materials. Therefore, container

42

can be made using an injection molding process or other molding processes as well known in the art.

Despite any methods being outlined in a step-by-step sequence, the completion of acts or steps in a particular chronological order is not mandatory. Further, elimination, modification, rearrangement, combination, reordering, or the like, of acts or steps is contemplated and considered within the scope of the description and appended claims.

Also, while the present invention has been described in terms of the preferred embodiment, it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the description and appended claims.