U.S. patent application number 10/797444 was filed with the patent office on 2004-09-30 for fiberboard pallet.
Invention is credited to Neary, Robin, Rojas, Jaime.
Application Number | 20040187745 10/797444 |
Document ID | / |
Family ID | 32994925 |
Filed Date | 2004-09-30 |
United States Patent
Application |
20040187745 |
Kind Code |
A1 |
Rojas, Jaime ; et
al. |
September 30, 2004 |
Fiberboard pallet
Abstract
The present invention relates to pallets including improved
structural supports suitable for use with various materials. In
accordance with one embodiment of the present invention, the pallet
includes a load supporting deck comprised of deck members, and
runners attached to the bottom of the load supporting deck, which
are comprised of structural supports supporting, in two planes, a
plank. The structural support of the present invention includes a
supporting wall, which has a top support surface and a side
surface, and a base support wall connected to the supporting wall
and which extends beyond the width of the supporting wall and
extends below the height of the supporting wall, such that the
supporting wall and base support wall define a plank supporting
edge for supporting a plank.
Inventors: |
Rojas, Jaime; (Miami,
FL) ; Neary, Robin; (Warren, NJ) |
Correspondence
Address: |
Steven B. Pokotilow, Esq.
Stroock & Stroock & Lavan LLP
180 Maiden Lane
New York
NY
10038
US
|
Family ID: |
32994925 |
Appl. No.: |
10/797444 |
Filed: |
March 10, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60458120 |
Mar 26, 2003 |
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Current U.S.
Class: |
108/51.11 |
Current CPC
Class: |
B65D 2519/00273
20130101; B65D 2519/00099 20130101; B65D 2519/00278 20130101; B65D
2519/00104 20130101; B65D 2519/0086 20130101; B65D 2519/00333
20130101; B65D 2519/00378 20130101; B65D 2519/00114 20130101; B65D
2519/00323 20130101; B65D 2519/00293 20130101; B65D 2519/00069
20130101; B65D 2519/00567 20130101; B65D 2519/00034 20130101; B65D
2519/00572 20130101; B65D 19/0095 20130101; B65D 2519/00562
20130101 |
Class at
Publication: |
108/051.11 |
International
Class: |
B65D 019/00 |
Claims
What is claimed is:
1. A pallet comprising: a load supporting deck having a first side
and a second side and including one or more first deck members; one
or more runners attached to the second side of the load supporting
deck, wherein each of the runners comprise one or more structural
supports and one or more planks attached to the one or more
structural supports, such that at least one of the structural
supports, in two planes, supports a plank.
2. The pallet of claim 1 further comprising a second deck having
one or more second deck members, wherein the one or more second
deck members are attached to, and supports, the one or more
structural supports.
3. The pallet of claim 2, wherein the one or more structural
supports include two substantially orthogonal sections, the two
sections defining an edge, the edge supporting the plank in the two
planes.
4. The pallet of claim 3, wherein the two sections include an
horizontal section and a vertical section, the two planes being
horizontal and vertical.
5. The pallet of claim 3, wherein the one or more structural
supports have a t-shaped profile.
6. The pallet of claim 3, wherein the one or more structural
supports have an inverted t-shaped profile.
7. The pallet of claim 3, wherein the one or more structural
supports have an l-shaped profile.
8. The pallet of claim 1, wherein the one or more load supporting
deck members are constructed of medium density fiberboard.
9. The pallet of claim 1, wherein the one or more structural
supports are constructed of high density polypropylene.
10. The pallet of claim 1, wherein the one or more structural
supports are constructed of polyethylene terephthalate.
11. The pallet of claim 1, wherein the one or more structural
supports are constructed of wood.
12. A structural support of a pallet, the structural support
comprising: a first supporting wall, wherein the first supporting
wall has a top support surface and a first side surface, and
wherein the first supporting wall has a first width and a first
height; and a first base support wall connected to the first
supporting wall, wherein the first support wall extends beyond the
first width and the first base support wall extends below the first
height, the first supporting wall and the first base support wall
thereby defining a first plank supporting edge to support a first
plank.
13. The structural support of claim 12, wherein the structural
support further comprises a second supporting wall, wherein the
second supporting wall has a top surface and a side surface, and
wherein the second supporting wall has a second width and a second
height; and wherein the first base support wall connects the first
and second supporting walls, wherein the first base support wall
extends beyond the first width and the second width and the first
base support wall extends below the first height and the second
height, the first supporting wall, the second supporting wall and
the first base support wall thereby defining a first plank
supporting edge to support a first plank.
14. The structural support of claim 13, wherein the structural
support further comprises a second base support wall connecting the
first and second supporting walls, wherein the second base support
wall extends beyond the first width and the second width and the
second base support wall extends below the first height and the
second height, the first supporting wall, the second supporting
wall and the second base support wall thereby defining a second
plank supporting edge to support a second plank.
15. The structural support of claim 12, wherein the top support
surface supports a deck member and the first side surface supports
a plank.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application No. 60/458,120, filed Mar. 26, 2003, which
is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to pallets, and, more
particularly, to pallets having improved structural supports
suitable for use with various materials.
[0004] 2. Description of Related Art
[0005] Pallets are typically flat, rectangular or square shaped
surfaces that are used to transport goods. Currently available
pallets are made from wood, paper, fiberboard, various plastics and
other substances. A typical industry standard pallet is rectangular
in shape and measures 48 inches by 40 inches.
[0006] One of the problems associated with the currently available
pallets are the strict exportation regulations required of such
packing materials. For example, wood packing materials, including
wood pallets currently are required to be kiln-dried or chemically
impregnated with a preservative. Documentation is required to
certify that wood packing materials, including wood pallets, are
acceptable for exportation. These strict exportation regulations
increase the costs associated with manufacturing wood pallets and
creates a risk that the product, upon importation to a country,
will be destroyed for failing to comply with the exportation
regulations.
[0007] Another problem associated with the currently available
pallets, and a further problem associated with the exportation
regulations, is the high cost of pallets that are exempt from the
wood packing exportation regulations. Corrugated and plastic
pallets are exempt from the wood packing exportation regulations;
however, these exempt pallets can be expensive to manufacture. For
example, pallets made completely from plastic can cost
approximately $50 each. Additionally, pallets are typically not
returned to the exporting company, which means that a high-cost
pallet can greatly increase the cost of the product being
exported.
[0008] Thus, there exists a need to provide a load-supporting
pallet having an improved structural support suitable for use with
various materials and that be constructed and assembled from
relatively lightweight, durable materials, which are relatively
inexpensive to manufacture.
SUMMARY OF THE INVENTION
[0009] The present invention satisfies the foregoing and other
needs. In one embodiment, the structural support of the present
invention supports fiberboard, wood, plastic or other suitable
planks and deck members, which preferably are relatively
lightweight and which are relatively inexpensive to
manufacture.
[0010] In accordance with one embodiment of the present invention,
the pallet includes a load supporting deck comprised of deck
members, and runners attached to the bottom of the load supporting
deck, which are comprised of structural supports supporting, in two
planes, a plank. The structural support of the present invention
includes a supporting wall, which has a top support surface and a
side surface, and a base support wall connected to the supporting
wall and which extends beyond the width of the supporting wall and
extends below the height of the supporting wall, such that the
supporting wall and base support wall define a plank supporting
edge for supporting a plank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The particular features and advantages of the invention as
well as other objects will become apparent from the following
description taken in connection with the accompanying drawings, in
which:
[0012] FIG. 1 is a three-dimensional top view illustrating a pallet
incorporating a structural support in accordance with one
embodiment of the present invention;
[0013] FIG. 2 is a three-dimensional top view illustrating a
structural support that may be used in an embodiment of the present
invention;
[0014] FIG. 3 is an side elevation view illustrating a durable
structural support that may be used in an embodiment of the present
invention.
[0015] FIG. 4 is an end elevation view illustrating a durable
structural support that may be used in an embodiment of the present
invention;
[0016] FIG. 5 is a three-dimensional side view illustrating a plank
attached to a structural support that may be used to assemble a
runner in accordance with an embodiment of the present
invention;
[0017] FIG. 6 is a three-dimensional side view illustrating a
second plank being attached to a structural support during assembly
of a runner that may be used in an embodiment of the present
invention;
[0018] FIG. 7 is a three-dimensional side view illustrating a
runner that may be used in an embodiment of the present
invention;
[0019] FIG. 8 is a three-dimensional bottom view of a runner that
may be used in an embodiment of the present invention; and
[0020] FIG. 9 is a three-dimensional view of a partially assembled
bottom deck in accordance with an embodiment of the present
invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0021] Certain exemplary embodiments of the present invention will
now be described with reference to the drawings. In general, such
embodiments relate to pallets constructed of lightweight, durable
materials, and, more particularly, to pallets constructed with
lightweight, durable structural supports, which can withstand rough
handling and heavy and high impact loads, as well as to support
members suitable for use in these and other pallets.
[0022] Turning to FIG. 1 pallet 10 includes a plurality of
longitudinally extending top deck members 12 supported by runners
20. Runners 20 typically include one or more planks 30, which
extend longitudinally in a non-parallel direction with respect to
deck members 12. Planks 30 typically rest upon one or more
structural supports 40 (shown in FIGS. 2, 3 and 4), the bottom
surfaces of which are attached to bottom deck members 18 in a
non-parallel direction with respect to runners 20. While the
majority of pallets rectangular, measuring 48 inches by 40 inches,
the present invention can be used to form pallets of any size and
shape. For example, a pallet could be a square or another polygon
having rail supports along one or more of the edges, or elsewhere.
The present invention can be used with any kind of pallet,
including those disclosed in U.S. Patent Nos. 5,067,418; 5,272,990;
5,816,172; 6,012,399; D419,275 and D419,774, which are herein
incorporated by reference.
[0023] As shown in FIG. 2, structural support member 40 has a
generally inverted T-shaped profile and includes supporting walls
42, base support walls 44, bottom surface 46 and top surfaces 48.
Structural support 40 also includes a plank supporting edge 50 and
a side wall 54 for supporting the planks 30.
[0024] Structural support 40 can be made from any durable
lightweight material that is capable of withstanding the required
loads, such as, for example, high density polypropylene (HDPP),
polyethylene terephthalate (PET), and wood. Structural support 40
can be molded in any manner known in the art, including, for
example, having a gate located on bottom surface 46, which connects
the left and right sides of structural support 40. In one
embodiment, structural support 40 is produced by injection molding
a high density polypropylene compound. In the embodiment depicted
in FIG. 2, structural support 40 has a hollow interior. However,
other embodiments may include differently configured interior
portions and solid interiors. FIG. 3 depicts a front wall 42 view
of structural support 40, while FIG. 4 depicts a side view of
structural support 40.
[0025] As will be appreciated by those skilled in the art,
structural support 40 of the present embodiment provides added
stability and durability by supporting at least two surfaces of the
planks 30, one surface contacting plank supporting edge 50 and
another surface contacting side wall 54. Furthermore, because
structural support 40 is supported on all sides (i.e., by planks 30
on each side, and top deck member 12 on the top and bottom deck
member 18 on the bottom), and includes plank supporting edges 50,
which planks 30 engage, the structural support 40 is resistant to
rotation, adding additional stability and durability.
[0026] The dimensions of structural support 40 can be varied as
desired to provide structural supports 40 that properly attach
planks 30 and top deck members 12 and bottom deck members 18, to
thereby form a pallet 10 that can withstand the applied loads. It
should be understood that the dimensions and proportions shown in
FIGS. 2, 3 and 4 are provided for purposes of illustration only,
and do not limit the invention to any particular dimensions or
portions. In a preferred embodiment, with reference to FIGS. 3 and
4, structural support 40 has a height (H) of 4", width (W) of 3"
and depth (D) of 5".
[0027] Furthermore, other configurations for structural support 40
are possible while staying within the scope of the present
invention. For example, structural support 40 can be solid.
Structural support can also be made with only one plank supporting
edge 50 and one side wall 54, i.e., having an L-shaped profile,
such that only one plank 30 is supported by edge 50 of structural
support 40 and, optionally, another plank supported by the opposite
wall. Structural support 40 can also be inverted, such that planks
30 engage the bottom deck members rather than top deck members.
[0028] Planks 30 may be made from any material that is suitable for
use in a pallet, such as, for example, wood, paper, medium density
fiberboard and plastic, and it is not required for all planks 30 to
be made from the same material in order to form pallet 10. In one
embodiment, plank 30 is made from a laminate. In another
embodiment, one or more planks 30 may be fiberboard laminates, such
as those manufactured by the BCI division of the Newark Group Inc.,
Cranford, N.J. under the trademark NEWPLANXS.
[0029] Plank 30, top deck members 12, bottom deck members 18 and/or
structural supports 40 may be designed to exhibit one or more
qualities that are desirable for pallets or to provide qualities
that will enhance the performance of a pallet that may be used for
ordinary or special purposes. For example, in one embodiment, plank
30 has the size and shape used to build a standard size pallet,
such as those that are currently made from wood and/or other known
pallet materials. In another embodiment, plank 30 is made water
resistant through any of a number of known processes, such as being
laminated or chemically treated. In yet another embodiment, plank
30 has sufficient hardness to withstand one or more particular
loading conditions. Plank 30 may also be designed such that it can
be manufactured using conventional pallet building tools.
[0030] The construction process of runners 20 of pallet 10 are
shown in FIGS. 5, 6, 7 and 8. As depicted in FIG. 5, one or more
runners 20 can be assembled by attaching a plank 30 to a first side
of structural support 40 at plank supporting edge 50. Any suitable
fastener can be used to attach planks 30 to support member 40
including, for example, slotted portions, protrusions or other
mating surfaces in planks 30 and/or structural supports 40,
staples, nails, screws, adhesives and any other known fastening or
securing mechanism. Additionally, planks 30 can have any desired
lengths and widths. A second plank 30 can be attached to a second
side of structural support 40 as shown in FIGS. 6-8.
[0031] Runners 20 may be provided in any size by cutting planks 30
to appropriate lengths and adjusting the location and/or number of
structural supports 40. In one embodiment, a plurality of
structural supports 40 are used with each of the one or more
runners 20. By way of example, a standard size pallet can be formed
using runners with 48" planks 30 and three structural supports 40.
Standard size pallets may also use fewer or more than three
structural supports per runner 20.
[0032] Pallet 10 can include a bottom deck 14 (illustrated in FIG.
9) and/or a top deck 16 (illustrated in FIG. 1). As depicted in
FIG. 9, runners 20 for a single pallet 10 can be positioned so that
structural support 40 of runner 20 aligns with the corresponding
structural supports 40 of different runners 20. The number and
distance (D) between runners 20 can vary and should be determined
based upon the load the will be supported by pallet 10 and based
upon other desirable features, for example, runners 20 can be
spaced to permit the insertion of the tines of a pallet jack. One
or more bottom deck members 18 can attach to bottom surfaces 46 of
structural supports 40 in a non-parallel direction with respect to
the longitudinal axis of runners 20 and can form bottom deck 14. In
one embodiment, bottom deck members 18 can be attached to
structural supports 40 in a direction perpendicular to the
longitudinal axis of runners 20. The bottom deck may also include
members attached to the bottom of planks 30.
[0033] Assembled bottom deck 14 and attached runners 20 can then be
rotated or otherwise adjusted to facilitate assembly of top deck
16. In one embodiment, top deck members 12 are attached to top
surfaces 48 of structural supports 40 and in one embodiment, the
direction of attachment of top deck members 12 to top surfaces 48
is a direction perpendicular to that of the longitudinal axis of
runner 20. For top deck 16, deck members 12 may be attached to a
plurality of runners 20 at top surfaces 48 of the aligned
structural supports 40. The number of bottom deck members 18 and
top deck members 12 used to form bottom deck 14 and top deck 16,
respectively, may or may not be the same, depending upon the manner
in which pallet 10 will be used, and the number of deck members
used to form either bottom deck 14 or top deck 16 may exceed that
of the other deck. In one embodiment, top deck 16 includes seven
top deck members 12 and bottom deck 14 includes three bottom deck
members 18.
[0034] Once assembled, pallet 10 will have the capabilities of
other pallets and may be used to transport goods and perform the
other tasks for which pallets are used. An assembled pallet may be
capable of receiving a forklift tine and may be assembled to
facilitate handling from all sides.
[0035] It is to be understood that certain changes may be made in
the above structures and construction without departing from the
spirit and scope of the invention. It is also intended that all
matter contained in the above description and shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense.
[0036] Those skilled in the art will recognize that the apparatus
of the present invention has many applications, may be implemented
in many manners and, as such, is not to be limited by the foregoing
exemplary embodiments and examples. In this regard, any number of
the features of the different embodiments described herein may be
combined into one single embodiment. Moreover, the scope of the
present invention covers conventionally known and future developed
variations and modifications to the apparatus described herein, as
would be understood by those skilled in the art.
* * * * *