Shipping unit

[0001] This application claims the benefit of provisional application Ser. No. 60/512,024, filed on Oct. 17, 2003.

[0002] This invention relates to an adjustable shipping tray particularly for shipping items of varying lengths. One example of the items of varying length is bath tiles. Many new and remodeled bathrooms now include a large single tile behind the bathtub against the back wall. These elongated tiles extend from one end of the bathtub to the other. Because of their length, these tiles are particularly susceptible to damage during shipping and transport to the installation site. At the same time, because of their length, these tiles are also expensive, such that breakage is particularly costly.

[0003] A shipping unit according to the present invention provides an adjustable shipping tray for shipping items of varying length.

[0004] The shipping unit of the present invention provides a first tray section and a second tray section. The first tray section includes parallel upper and lower bottom walls which define a slot there between, opposed side walls, an end wall, and an open end opposite the end wall. A forward portion of the lower bottom wall extends adjacent to the open end. The second tray section defines a bottom wall, opposing side walls, an end wall, and an open end opposing the end wall. A forward tongue extends forwardly away from the open end and is received within the slot of the first tray section such that the first and second tray sections are connected and may be moved relative to one another to accommodate tiles of varying lengths. The first and second tray sections further include base portions extending downwardly from the bottom walls for stacking of the shipping units.

[0005] In a second embodiment, the shipping unit includes a tray with open side walls and a lid connected to one of the side walls via a hinge. The lid includes an outwardly projecting tab and a slot on the opposite end of the lid from the tab. The shipping units are connected by snap fitting the tab of one shipping unit into the slot of another shipping unit.

[0006] The shipping unit of the present invention provides a stackable shipping tray that protects objects, such as costly tiles, when shipping and easily adjusts to accommodate various lengths of objects.

[0014] A shipping unit 10 in accordance with a first embodiment of the present invention is shown in FIG. 1. The shipping unit 10 includes a first tray section 12 and a second tray section 14. The first tray section 12 includes an upper bottom wall 16 and a lower bottom wall 18 generally parallel to one another and spaced apart to define a slot 19. One or more holes 20 may also be formed in the upper bottom wall 16.

[0015] The first tray section 12 further includes a pair of opposed side walls 22 extending upwardly from the upper and lower bottom walls 16, 18. The first tray section 12 further includes an end wall 24 extending upwardly from the upper bottom wall 16. A handle 26 is formed on an exterior surface of the end wall 24. The first tray section 12 includes an open end 27 opposite the end wall 24. A forward portion 28 of the lower bottom wall 18 is adjacent the open end 27. The upper bottom wall 16 does not extend above the forward portion 28 of the lower bottom wall 18. The first tray section 12 further includes base portions 29 extending downwardly.

[0016] The second tray section 14 includes a bottom wall 36 up from which extend opposing side walls 42 and an end wall 44. The handle 46 is formed on an exterior surface of the end wall 44. The second tray section 14 has an open end 47 opposite the end wall 44. A forward tongue 48 extends forwardly away from the open end 47 of the second tray section 14. The second tray section 14 includes a base portion 49 extending downwardly.

[0017] The forward tongue 48 of the second tray section 14 is received within the slot 19 of the first tray section, between the upper bottom wall 16 and the lower bottom wall 18. The side walls 42 of the second tray section 14 are slidably received between the side walls 22 of the first tray section 12. The bottom wall 36 of the second tray section 14 is supported on the forward portion 28 of the lower bottom wall 18 of the first tray section 12. In this manner, the first and second tray sections 12, 14 are connected and may be moved relative to one another to create a shipping unit 10 of variable length.

[0018] Referring to FIG. 2, the shipping unit 10 is also stackable on similar shipping units 10a, 10b. The base portions 29, 49 of the upper shipping unit 10 are supported on the side walls 22a, 42a of the lower shipping unit 10a.

[0019] Referring to FIG. 3, in use, the trays 10 are adjusted to the proper length to accommodate the particular items, which in the example illustrated are bath tiles 50. The bath tiles 50, 50a, 50b are then placed inside the shipping units 10, 10a, 10b, respectively. For storage and for shipping, the trays 10 can be stacked upon one another while protecting the bath tiles 50. The tiles 50 and trays 10 can be carried by handles 26, 46. Although the invention is described for use with bath tiles 50 for purposes of illustration, the invention can be used for any items that may have varying lengths.

[0020] A shipping unit 60 according to a second embodiment of the present invention is shown in FIG. 4. The shipping unit 60 includes a tray 62 and lid 64. The tray 62 generally comprises a bottom wall 66 from which base portions 68 extend downwardly. Side walls 70 extend upwardly from opposite sides of the bottom wall 66, while opposite ends between the side walls 70 are open. The lid 64 is connected to one of the side walls 70 via a hinge 72. One of the ends of the lid 64 adjacent the hinge 72 includes a tab 76 projecting outwardly, while the opposite end of the lid 64 includes a complementary slot 78 into which a tab 76 of a lid 64 of a similar shipping unit 60 can be snap fit.

[0021] Referring to FIG. 5, the lid 64 includes a latch 80 at a side edge opposite the hinge 72. The latch 80 snap fits over the side wall 70 when the lid 64 is in the closed position. As shown in FIG. 5, the shipping unit 60 can be connected to multiple shipping units, such as 60a, to accommodate items of different lengths. The shipping units 60, 60a are connected by snap fitting the tab 76a (not visible) of one shipping unit 60a into a slot 78 (shown in FIG. 4) of the other shipping unit 60. In use, as many shipping units 60 as are needed to accommodate the entire length of the item 82 would be connected. In this manner, the multiple, connected shipping units 60, 60a can accommodate items 82 of various lengths. Again, although in the illustrated example, the items 82 are bath tiles the invention would also be useful for other items. As shown in FIG. 5, the two shipping units 60, 60a are connected together. The bath tile 82 is then laid in the shipping units 60, 60a and the lids 64 are closed. The bath tile 82 is stored and shipped in the connected shipping units 60, 60a, in which the bath tile 82 is protected. Additionally, as shown in FIG. 6, these shipping units 60, 60a may be stacked upon additional connected shipping units 60b, 60c also containing bath tiles 82b, 82c.

[0022] While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.