U.S. patent application number 10/939933 was filed with the patent office on 2006-03-16 for wooden dowel in pallet assembly.
Invention is credited to Michael R. Miller, Andrew P. Studdert.
Application Number | 20060054064 10/939933 |
Document ID | / |
Family ID | 36032508 |
Filed Date | 2006-03-16 |
United States Patent
Application |
20060054064 |
Kind Code |
A1 |
Miller; Michael R. ; et
al. |
March 16, 2006 |
Wooden dowel in pallet assembly
Abstract
An improved pallet that is capable of easy assembly,
functionally adequate for some situations and capable of easy
disassembly. In one form of the invention, a pallet is provided
that is made of all wood. In one embodiment, the pallet may be
comprised of a plurality of stringers with bores, a plurality of
deck boards with openings, and a plurality of wooden dowels
disposed in the bores and openings to connect the stringers and
deck boards.
Inventors: |
Miller; Michael R.;
(Winnetka, IL) ; Studdert; Andrew P.; (Wilmette,
IL) |
Correspondence
Address: |
WELSH & KATZ, LTD
120 S RIVERSIDE PLAZA
22ND FLOOR
CHICAGO
IL
60606
US
|
Family ID: |
36032508 |
Appl. No.: |
10/939933 |
Filed: |
September 13, 2004 |
Current U.S.
Class: |
108/56.1 |
Current CPC
Class: |
B65D 2519/00323
20130101; B65D 2519/00099 20130101; B65D 2519/00298 20130101; B65D
2519/00293 20130101; B65D 2519/00029 20130101; B65D 2519/00278
20130101; B65D 2519/00373 20130101; B65D 2519/00273 20130101; B65D
19/0095 20130101; B65D 2203/10 20130101; B65D 2519/00562 20130101;
B65D 2519/00333 20130101; B65D 2519/00064 20130101; B65D 2519/00572
20130101; B65D 2519/00353 20130101 |
Class at
Publication: |
108/056.1 |
International
Class: |
B65D 19/16 20060101
B65D019/16; B65D 19/12 20060101 B65D019/12 |
Claims
1. A method for assembling a pallet comprising: providing a
plurality of dowels, each dowel comprising first and second
portions, each dowel having at least two contiguous dowel sections
having sidewalls of different cross-sectional size; providing at
least two elongated stringers, each stringer having a longitudinal
mounting surface having a plurality of bores formed therein in
spaced relation along the mounting surface, the bores each being
configured to receive a selected portion of one of the dowels;
providing a plurality of deck boards, each deck board having first
and second ends with each end having an opening adapted for aligned
relation with a selected bore in one of the stringers, the openings
configured to receive a remaining portion of the dowel; applying
adhesive material to at least part of the longitudinal mounting
surface of the stringers, to at least part of the first and second
ends of the deck boards, and to the openings, bores, or dowels such
that adhesive material is ultimately disposed in the bores and
openings; positioning the stringers and deck boards in a
predetermined orientation; inserting the dowels into the openings
of the deck boards and into the aligned bores of the stringers in a
snug relationship to thereby connect the deck boards to the
stringers and assemble the pallet and allowing the adhesive to
cure.
2. The method of claim 1, wherein the dowel is wooden.
3. The method of claim 1 wherein the adhesive material is applied
so that it is disposed on substantially all of the longitudinal
mounting surfaces of the stringers, first and second ends of the
deck boards, and to the openings, bores, and dowels.
4. The method of claim 1, further comprising attaching an RFID
device to the pallet.
5. The method of claim 1, further comprising creating the openings
and the bores with a drill.
6. The method of claim 1 wherein the stringers and end boards are
comprised of dry wood.
7. The method of claim 1 wherein the pallet meets industry
standards for a rated load of 2800-pounds and weighs less than 60
pounds.
8. The method of claim 1 wherein the dowels are wooden with at
least partially grooved sidewalls.
9. The method of claim 1 wherein the dowels are wooden and have at
least three dowel sections of successively decreasing
cross-sectional sizes.
10. The method of claim 9 wherein the dowels have cylindrical dowel
sections.
11. The method of claim 1 wherein the dowels are wooden with at
least partially ribbed sidewalls.
12. The method of claim 1 wherein the dowels form a friction fit
with the openings and bores.
13. The method of claim 1 wherein the adhesive is capable of curing
without the use of external clamps.
14. A substantially wooden pallet comprising: a plurality of
stringers, each including a longitudinal mounting surface having a
plurality of bores formed therein; a plurality of deck boards
having first and second ends, each end having at least one opening;
and a plurality of dowels, each dowel having first and second
portions, wherein the first portions and an adhesive are inserted
in the plurality of stringer openings and the second portions and
the adhesive are inserted into the deck board openings such that
the deck boards are connected to the stringers in a predetermined
orientation to form a pallet, wherein each of the dowels comprises
at least two contiguous dowel sections having sidewalls of
different cross-sectional size
15. A pallet as defined in claim 14 wherein the adhesive is
disposed in the bores and openings and on the stringers and deck
boards to more securely connect the panel boards to the
stringers.
16. A pallet as defined in claim 14 wherein the dowels are wooden
and the sidewalls are at least partially grooved.
17. A pallet as defined in claim 14 wherein the dowels include at
least three contiguous dowel sections of successively decreasing
cross-sectional size.
18. A pallet as defined in claim 17 wherein the dowel is wooden and
the at least three contiguous dowel sections are cylindrical.
19. A pallet as defined in claim 14 wherein the dowel sidewalls are
at least partially ribbed.
20. A pallet as defined in claim 14, further comprising an RFID
device attached to the pallet.
21. A pallet as defined in claim 14, wherein the stringers and deck
boards are comprised of dry wood.
22. A pallet as defined in claim 14, wherein the pallet meets the
industry standards for a rated load of 2800-pounds and weighs less
than 60 pounds.
23. A substantially wooden pallet comprising: a plurality of
stringers, each stringer having a width and an elongated
longitudinal mounting surface, the mounting surface having an
inside section and notched ends, the notched ends having a notch
depth, wherein the stringers are orientated in substantially the
same plane in a parallel relationship; a plurality of deck boards
having a deck board width and first and second board ends; a
plurality of lead deck boards having a lead board height and first
and second lead board ends a plurality of fasteners, wherein the
fasteners fasten the first board ends to the inside section of a
first stringer and the second board ends to the inside section of a
second stringer and the fasteners fasten the first lead board ends
to the notched ends of a first stringer and the second lead boar
ends to the notched ends of a second stringer, wherein the deck
boards and lead deck boards are substantially parallel to each
other and are transverse to the stringers, wherein the lead board
height is substantially equal to the sum of the notch depth and
deck board width.
24. The pallet of claim 23, wherein the fasteners are wooden dowels
comprising at least two contiguous dowel sections having sidewalls
of different cross-section sizes.
25. The pallet of claim 24, wherein the stringers have a plurality
of bores formed therein configured to receive a first portion of
the dowel and the deck boards and lead deck boards have a plurality
of openings formed therein configured to receive a second portion
of the dowel.
26. The pallet of claim 23 wherein an adhesive is disposed in the
bores and openings and between the stringers and deck boards and
lead deck boards.
27. The pallet of claim 23 wherein the dowels allow the adhesive to
cure without the use of external clamps.
28. The pallet of claim 23, wherein the pallet consists essentially
of wood and adhesive.
29. The pallet of claim 28, wherein the stringers and deck boards
are dry wood.
30. The pallet of claim 24 further comprising an RFID device
attached to the pallet.
31. A substantially wooden pallet comprising: a plurality of
stringers, each stringer including a longitudinal mounting surface
having a plurality of bores formed therein, wherein the stringers
are comprised of dry wood; a plurality of deck boards having first
and second ends, each end having at least one opening, wherein the
deck boards are comprised of dry wood; a plurality of dowels, each
dowel having first and second portions, wherein the first portions
and an adhesive are inserted in the plurality of stringer openings
and the second portions and the adhesive are inserted into the deck
board openings such that the deck boards are connected to the
stringers in a predetermined orientation to form a pallet, wherein
each of the wooden dowels comprises at least two contiguous dowel
sections having sidewalls of different cross-sectional size; and an
RFID device attached to an inner surface of a stringer or deck
board, wherein the pallet comprises no metal.
32. The pallet of claim 31, wherein the dowels are comprised of
wood.
33. The pallet of claim 32, wherein the adhesive substantially
covers the ends of the deck boards
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to pallets, and more
particularly to a pallet having deck boards connected to stringers
with wooden dowels having stepped diameter peripheral surfaces
which act as internal clamps.
BACKGROUND OF THE INVENTION
[0002] Pallets of various types are known in the art. Typical
pallets are constructed of wood and include parallel stringers to
which transverse deck boards are then nailed or otherwise secured
with metal fastener devices to form the pallet. Pallets need to
have sufficient strength to withstand the weight of objects loaded
thereon and other impact forces to which the pallets are subjected
when objects are loaded onto them and when the pallets are moved,
as by a fork-lift truck or the like.
[0003] In many pallets, pallets are damaged at their lead boards.
As a fork lift or other mechanism is brought to engage a pallet, it
will often impact the lead board of the pallet with significant
force. This shearing force may disengage the lead board or
otherwise damage it, yielding a worn or damaged pallet that may not
work as well and may be dangerous to users and merchandise.
[0004] Also, as pallets are used, they can become worn and
weakened, causing some of the stringers or deck boards to break or
become at least partially detached, rendering the pallet inoperable
or in a dangerous condition. The use of nails or other metal
fastener devices can also render pallets dangerous. Many times, the
damage to a pallet occurs where the metal nail goes into the wood.
The use of metal fasteners can cause checking in the stringers or
deck boards. Further faults include product damage or personal
injury caused by exposed fasteners and inadequate joint
stiffeners.
[0005] In an effort to save money and resources, the undamaged
portions of worn or damaged pallets are often salvaged and reused
in making recycled pallets, used as fuel or sawdust, or put to
other uses. Those in the art have employed many methods in their
attempts to salvage worn-out pallets by stripping or otherwise
disassembling the stringers and deck boards from each other.
However, many of these methods require costly machinery or a great
deal of time and effort and put workers at significant safety risk.
Nails and other metallic fasteners are often a great hindrance in
efforts to disassemble pallets. The presence of, for example, nails
prevents the use of standard saws or similar devices, which do not
effectively cut through nails. Devices that are able to disassemble
worn-out pallets that include nails face other disadvantages.
First, they are often large, unwieldy and expensive. Second, often
times the nails remain in the stringers or deck boards after
disassembly. In order to reuse the boards in optimal condition, the
nails need be removed, requiring additional time with attendant
increased cost and expense.
[0006] More recently, companies who utilize pallets have turned to
Radio Frequency Identification ("RFID") technology to monitor and
track pallet location and other information. To use such
technology, encoded RFID tags or devices are placed on a pallet. As
the pallet moves through distribution channels, RFID readers scan
the devices. By, for example, placing a RFID reader at a dock door
of a warehouse, a supplier and customer know when a pallet arrives.
Wal-Mart has imposed RFID deadlines on its major suppliers.
However, there have been problems implementing RFID systems. One
problem that faces RFID technology is the ability to read metal
products because metal can prevent RFID readers from operating
properly. A pallet without metallic fasteners would thus be
desired. Further, liquid inside of objects can absorb RF signals,
making reading more difficult. It is thus desirable to have a
wooden pallet that can be constructed with drier wood. However,
nails and other metallic fasteners often cannot be used to
construct a pallet with dry wood because they will cause checking
and damage to the wood during construction.
[0007] In response to these problems, construction of pallets
without utilizing metallic fasteners has been attempted. One such
method uses only adhesives to connect stringers to deck boards.
However, there are numerous disadvantages to such a pallet. One is
that the connection is often times not strong enough to resist
typical shearing or other forces. A second disadvantage to such a
pallet is the required use of external clamps or similar devices to
hold the pieces together while the glue sets. A third disadvantage
of this technique is the waste of time between initial alignment
and ultimate formation of the pallet. This waste of time stems from
the requirement of waiting for the glue to set before use of the
pallet. There thus exists a need for a pallet that can be readily
and economically assembled, can withstand substantial impact and
load forces, can be easily disassembled, including with dry wood,
and will not interfere with RF signals or prevent RFID readers from
operating properly.
SUMMARY OF THE INVENTION
[0008] In carrying out one embodiment of the invention, a pallet
made predominately of wood comprises a plurality of wooden
stringers. Each wooden stringer comprises four elongated
longitudinal surfaces and two end surfaces. A selected longitudinal
surface is designated as a mounting surface and has a plurality of
bores formed therein so that the longitudinal axes of the bores are
generally normal to the mounting surface. The size and shape of the
bores can range from a depth completely through the stringer to a
smaller depth sufficient to receive a portion of a dowel.
[0009] The deck boards can be connected to the stringers by a
plurality of wooden dowels. Each of the dowels preferably has a
first and second portion. The dowel comprises at least two
contiguous dowel sections having different cross-sectional size.
The dowels are preferably constructed so that one portion fits into
one of the bores in the stringer while the other portion fits into
one of the openings in the deck board, thereby connecting the
stringer to the deck board. Adhesive is used to augment that
connection. The second end of the deck board can be similarly
connected to a second stringer so that the deck board is transverse
the wooden stringers. A pallet can be formed by so connecting a
plurality of deck boards to the stringers.
[0010] One benefit of the present invention is to provide a pallet
that can be easily assembled through the use of wooden dowels that
facilitate attachment of transverse deck boards to parallel
stringers in a quick and efficient manner.
[0011] Another benefit of the present invention is to provide a
pallet of the aforedescribed type that may in one embodiment employ
an adhesive in conjunction with the dowels, the dowels being
configured to eliminate the need for external clamps to hold the
parts together while the adhesive sets or cures. Thus, there is no
time wasted after initial alignment and connection because the
dowels provide sufficient connectivity to allow for immediate
handling and use of the formed pallets.
[0012] Another benefit of the present invention is to provide a
pallet that works properly. The dowels provide for a connection
that is sufficiently strong to resist standard shear and other
forces.
[0013] Another benefit of the present invention is to provide a
pallet that can be more easily disassembled. In the preferred
embodiment the dowels are made of wood; therefore, the pallet can
be more readily stripped or broken down using standard wood-cutting
saws. This allows for an increased number of customers for used or
worn pallets, because those customers have no need for specialty
equipment to grind up nails.
[0014] Another benefit of the present invention is to provide a
pallet which can be a carrier of RFID technology. Because the
preferred embodiment does not have metal, the pallet will not
prevent RFID readers from working properly. The pallet claimed
herein can have a RFID device placed on it, and it will be able to
be read by RFID readers without fear of a nail or other metal
fastener preventing the RFID reader from working properly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The features of the present invention which are believed to
be novel are set forth with particularity in the appended claims.
The drawings may not be to scale. The invention may best be
understood by reference to the following description taken in
conjunction with the accompanying drawings, in the several figures
of which like reference numerals identify like elements, and in
which:
[0016] FIG. 1 is a perspective view of one embodiment of a deck
board and stringer that may be used in the pallet of the subject
invention;
[0017] FIG. 2 is an elevated side view of one embodiment of a dowel
used in the pallet of FIG. 1;
[0018] FIG. 3 is an end view of the embodiment of the dowel
depicted in FIG. 2;
[0019] FIG. 4 is a side view of one embodiment of a dowel utilized
in the subject invention to connect a stringer to a deck board.
[0020] FIG. 5 is a side view of another embodiment of a dowel
utilized in the subject invention to connect a stringer to a deck
board.
[0021] FIG. 6 is a perspective view of one embodiment of the
subject invention showing a pallet comprising stringers, deck
boards and dowels.
[0022] FIG. 7 sets forth the steps in one embodiment of a method
for assembling a pallet according to the subject invention.
[0023] FIG. 8 is a side view of another embodiment of the subject
invention showing a pallet with a notched stringer.
DETAILED DESCRIPTION
[0024] While the present invention is susceptible of embodiments of
various forms, there is shown in the drawings, and will hereinafter
be described some exemplary and non-limiting embodiments, with the
understanding that the present disclosure is to be considered an
exemplification of the invention. It is not intended to limit the
invention to the specific embodiments listed.
[0025] In general terms, one embodiment of the pallet comprises the
combination of wooden dowels and adhesive to connect stringers and
deck boards to form a pallet.
[0026] Referring to FIG. 1, a deck board 10 and a stringer 30 can
be seen. The deck board 10 has a first end 11 and a second end 12.
The deck board 10 comprises a first pair of opposing elongated
longitudinal surfaces 9, 14 with a first width 15, a second pair of
opposing elongated longitudinal surfaces 16, 17 with a second width
18 and a pair of end surfaces 19, 20. The first width 15 is greater
than the second width 18. Both the first end 11 and the second end
12 have at least one opening 13. Preferably, the openings are in
the same elongated surface 16, 17, 19, 20. More preferably, the
openings 13 are in one of the first pair of elongated surfaces 16,
17. In one embodiment, both the first end 11 and the second end 12
have a plurality of openings 13. The openings 13 have an inner
surface 84. Preferably, the deck board 10 is constructed of wood or
like material. Along with first and second ends 11, 12 the deck
board 10 can also have a middle section 21, wherein the middle
section 21 has at least one opening 13 preferably in the same
elongated surface 16, 17, 19, 20 as the openings 13 in the first
and second ends 11, 12.
[0027] The stringer 30 comprises a first pair of opposing
longitudinal mounting surfaces 31, 32 which have a first width 33.
The stringer 30 further comprises a second pair of opposing
longitudinal mounting surfaces 34, 35 which have a second width 36.
The second width 36 is greater than the first width 33. The
stringer 30 further comprises a pair of opposing end surfaces 37,
38. At least one of the longitudinal mounting surfaces 31, 32, 34,
35 has a plurality of bores 39 defined therein. The terms bore and
opening are herein used synonymously. The different terms are used
to more easily reference stringer (having bores) or deck board
(having openings). The bores 39 have an inner surface 88. In one
embodiment, the plurality of bores 39 are spaced substantially
equally along a longitudinal mounting surface 31, 32, 34, 35. In
another embodiment, opposing longitudinal surfaces, either 31, 32
or 34, 35, both have a plurality of bores 39. Preferably, the
stringer 30 is made of wood or like material.
[0028] Referring to FIG. 2, one embodiment of a wooden dowel 50 can
be seen. The dowel 50 comprises a first portion 52 and a second
portion 54. The dowel may have a plurality of dowel sections, a
first section 56, middle sections 58, 60, and last section 62.
While in a preferred embodiment, the dowel 50 has two middle
sections 58, 60 other embodiments may have no middle section, one
middle section, or three or more middle sections. The first and
last sections 56, 62 may have side walls 64, 66 and end walls 68,
70, respectively. Each of the middle sections 58, 60 may have side
walls 72, 74 and step walls 76, 78, respectively. In a preferred
embodiment, each of the sections 56, 58, 60, 62 are contiguous to
another section 56, 58, 60, 62. The sidewalls 64, 66, 72, 74 define
a cross-sectional size for their respective sections 56, 58, 60,
62. In a preferred embodiment, the cross-sectional size of the
sidewalls 64, 66, 72, 74 decreases as one progresses from the first
section 56 to the last section 62 in a number of steps. In another
embodiment, the cross-sectional size of the sidewalls is greatest
in a middle section (not shown). The cross-sectional size of the
sidewalls 64, 66, 72, 74 may be any suitable size. The length of
each individual dowel section 56, 58, 60, 62 may vary considerably.
In one embodiment, the dowel section 656, 58, 60, 62 with the
smallest cross-sectional size is as long or longer than the length
of any of the other dowel sections. The dowel 50 may have some
sections, e.g., 58, 60 or all sections 56, 58, 60, 62 that have
grooves 80. The dowel 50 may have other configurations, such as,
the dowel shown and described in U.S. Pat. No. 6,267,527, which is
hereby incorporated by reference.
[0029] As shown in FIG. 3, an embodiment is depicted having dowel
sections 56, 58, 60, 62 having a circular configuration. Other
embodiments of the dowel 50 may be constructed so that each dowel
section has a substantially square, triangular, or other
cross-section. Further embodiments may mix and match square
sections with triangular sections, or try other combinations. It is
preferred that the dowel 50 be constructed from a single integral
piece of wood. The dowel 50 may be constructed of different pieces
of wood that are functionally attached to form the dowel 50. The
dowel 50 is preferably made substantially of birch, but may also be
made of red oak, cherry, ash, beech, or other suitable preferably
hardwoods.
[0030] As shown in FIG. 4, the dowel 50 connects the stringer 30
and the deck board 10. The opening 13 of the deck board 10 is
configured to receive either the first or second portion 52, 54 of
the dowel 50. The opening 13 is preferably sized so that it is
slightly smaller than the dowel portion 52, 54 that it is
configured to receive. The dowel 50 may fit snugly into the opening
13. Preferably, the dowel 50 and the opening 13 form a friction
fit. In a preferred embodiment, the dowel 50 can be partially
inserted into the opening 13 by hand. Because of the stepped nature
of the dowel 50, the dowel 50 can be partially inserted into the
opening 13 with minimal force. The partially inserted dowel 50 in
the opening 13 of the deck board 10 is aligned with a selected bore
39 of the stringer 30. The selected bore 39 can configured to
receive the portion of the dowel 50, either first or second 52, 54,
that the opening 13 of the deck board 10 has not received. Again,
because of the stepped nature of the dowel 50, the dowel can be
partially inserted into the bore 39 with minimal effort. Through
the ability to be partially inserted with minimal force, the dowel
50 provides proper alignment of the opening 13 with the bore 39.
The dowel 50 can be substantially or fully inserted into the
opening 13 and bore 39 through the use of a suitable pounding
device (not shown), such as a hammer or mallet, or through manual
strength. The dowel 50 may fit snugly into the selected opening 13
and bore 39. Preferably, the dowel 50 and the opening 13 and bore
39 form a friction fit. Preferably, adhesive (not shown) is
disposed between the abutting parts of the dowel 50, stringer 30
and deck board 10.
[0031] As can be seen in FIG. 4, once the dowel 50 is inserted into
the opening 13 and the bore 39, the deck board 10 and stringer 30
are connected. Preferably, the deck board 10 and stringer 30 will
be aligned transverse each other. The deck board 10 may form a
right angle with the stringer 30.
[0032] Referring now to FIG. 5, a second embodiment of the
connection between a selected stringer 30 and a selected deck board
10 can be seen. In this embodiment, the opening 13 is such that it
defines a hole 82 through the deck board 10. In other embodiments,
the bore 39 defines a hole 82 through the stringer 30, or both the
bore 39 and the opening 13 define holes 82 in the stringer 30 and
deck board 10, respectively. An advantage of this embodiment is
that it allows the dowel 50 to be more easily inserted into both
the deck board 10 and stringer 30 almost simultaneously. This
embodiment also allows for one-step desired alignment of the
opening 13 with the bore 39. In this embodiment, the opening 13 and
bore 39 can be created at the same time using a properly shaped
drill (not shown) or other suitable device. The drill bit (not
shown) used with a drill may have many configurations, such as the
drill bit shown and described in U.S. Pat. No. 6,267,527, which is
hereby incorporated by reference. The deck board 10 can be placed
in a predetermined alignment with the stringer 30. An operator can
then drill a hole 82 through the deck board 10, creating the
opening 13, and then continue to drill into the stringer 30 to
create the corresponding bore 39.
[0033] Referring now to FIG. 6, an embodiment of the pallet is
depicted as having three stringers 30 orientated in substantially
the same plane in a parallel relationship. Many other pallet
configurations may be used including, e.g., the stringer design,
the block design, skids, stevedore type double wing, plywood panel
deck stringer, nine block four-way entry pallet, single wing pallet
with optional chamber on bottom boards, or the reversible stringer
pallet. This list is given as an example of some types of pallets,
and is not intended to be exhaustive. One of skill in the art would
recognize that a wide variety of pallet formations can be
contemplated and would fall within the scope of the invention.
[0034] As shown in FIG. 6, one embodiment may have first, second,
and third stringers 30 arranged parallel to each other. The second
stringer 30 is spaced a substantially equal space from the first
and third stringers 30, respectively. The distance between the
first and third stringer 30 is substantially equal to the length of
a pre-selected deck board 10. Each of the first pair of opposing
longitudinal mounting surfaces 31, 32 has a plurality of bores 39
(some not shown) defined therein The embodiment may have a
plurality of deck boards 10 arranged parallel to each other and
transverse to the stringers 30. Preferably, one of the first pair
of opposing elongated longitudinal surfaces 9, 14 of each deck
board 10 has a plurality of openings 13 (some not shown) defined
therein. The deck boards 10 are arranged such that the openings 13
defined in the first end 11, second end 12 and middle section 21
are aligned with the bores 39 defined in the stringers 30. A
plurality of dowels 50 are fit into the openings 13 and aligned
bores 39 to connect the stringers 30 to the deck boards 10. One set
of deck boards 10 are connected opposing longitudinal mounting
surface 31 while a second set of deck boards 10 are connected to
opposing longitudinal mounting surface 32.
[0035] FIG. 7 sets forth the steps of a preferred method for
forming a pallet. It should be noted that FIG. 7 gives numbers to
Parts of the method for ease of reference only. The invention can
be performed in an order different than that provided. The
reference numerals, e.g. dowel 50, provided below refer to FIGS.
1-6.
[0036] Part 1 of FIG. 7 recites the step of providing a plurality
of wooden dowels 50. Each of the dowels 50 comprises first and
second portions 52, 54 and has at least two contiguous dowel
sections 56, 62 having sidewalls 64, 66 of different
cross-sectional size. The dowels 50 may be of the type shown in
FIGS. 2-6 and described above.
[0037] Part 2 recites providing of at least two elongated stringers
30. Each stringer 30 has a longitudinal mounting surface 31 having
a plurality of bores 39 formed therein in spaced relation along the
mounting surface 31. The bores 39 are configured to receive a
selected portion 52, 54 of one of the dowels 50.
[0038] Part 3 describes the step of the providing of a plurality of
deck boards 10. Each of the deck boards 10 has first and second
ends 11, 12 with each end having an opening 13 adapted for aligned
relation with a selected bore 39 in one of the stringers 30. The
openings 13 are configured to receive a remaining portion 52 or 54
of the dowel 50. The bores 39 and openings 13 can be configured
with the use of a drill (not shown) with attendant drill bit (not
shown). The drill bit may have many configurations, such as, e.g.,
the drill bit shown and described in U.S. Pat. No. 6,267,527, which
is hereby incorporated by reference. Preferably, the stringers 30
and deck boards 10 provided are comprised of a dry wood. The method
can further comprise providing an RFID device (shown as 110 in
FIGS. 6 and 8) to be attached to the pallet.
[0039] Part 4 recites the application of adhesive material (not
shown) to the stringers 30 and deck boards 10 such that some of the
adhesive material is disposed in the bores 39 and openings 13. The
adhesive material may be applied to the surfaces 31, 32, 34, 35,
13, 14, 16, 17, of the stringers 30, deck boards 10 or side walls
64, 66, 72, 74 of the dowels 50 to strengthen or augment the
connection. The adhesive material is preferably PVA, but can be any
material that would adequately connect the parts of the pallet
together, such as, e.g., elastomers, hot melts, urethane, epoxy,
PRF, or urethane/isocyanate. Preferably, during the construction of
a pallet, the adhesive is applied to the stringers 30 and deck
boards 10 such that some of the adhesive is disposed in the bores
39 and openings 13 prior to the insertion of the dowels 50. The
adhesive material may also be applied to the side walls 64, 66, 72,
74 of the dowel 50. In a preferred embodiment, the adhesive applied
to the dowel 50 is thinned to allow for more ready insertion and
connection. As the dowel is inserted into the bore or opening 13,
the adhesive material may be at partly scraped from the side walls
64, 66, 72, 74 to accumulate on the end wall 70 and step walls 76,
78.
[0040] Part 5 recites the positioning of the stringers 30 in
parallel relation with the mounting surfaces 31, 32 of different
stringers 30 in substantially coplanar relation, and positioning
the deck boards 10 in parallel relation transverse to the mounting
surfaces 31, 32.
[0041] Part 6 recites the insertion of the dowels 50 into the
openings 13 of the deck boards 10 and into the aligned bores 39 of
the stringers 30 in a snug relationship to thereby connect the deck
boards 10 to the stringers 30. The stepped configuration of the
dowel 50 provides easier alignment of the dowel 50 with the opening
13 and bore 39 during the insertion process. Further, significant
pressure need be only applied to the dowel 50 during, for example,
approximately the last 20 percent of the insertion distance. A
pounding device (not shown) may be used to insert the dowels. This
device may be a hammer, mallet, or other suitable instrument.
Preferably, the dowels 50 fit snugly into the openings 13 and bores
39. Most preferably, the dowels 50 form a friction fit with the
inner surface 84, 88 of the opening 13 or bore 39. The snug or
friction fit connects the deck boards 10 to the stringer 30. Using
a dowel 50 with grooves 80 yields a connection that is stronger.
One benefit of the dowel 50 is that it acts as an internal clamping
mechanism that holds the pallet together while the adhesive sets or
cures. This benefit provides needing flexibility to the
manufacturing process, allowing more ready manufacture of pallets.
For example, the use of the dowels 50 can eliminate the need for
external clamps or other devices (not shown) to maintain connection
of the deck boards 10 to the stringers 30 while the adhesive cures.
The manufacturer can thus avoid the costs of these external clamps
as well as the time, effort, and floor space needed to utilize
them. A second benefit of the use of the dowel 50 is that it can
allow for the use of a wide variety of adhesive materials. A pallet
manufacturing operations using adhesives may have the capability of
manufacturing a number of pallets per unit time. However, the need
for space to allow for the adhesive in the pallets to set or cure
is great. Typically, these operations will thus prefer adhesives
with very short set or cure times, even though these adhesives are
not optimal on a cost or performance basis. The use of the dowel 50
to connect the runners 10 to the stringers 30 allow for the
practical use of adhesives with longer cure times because the
pallet can be handled and used while the adhesive is setting or
curing. It also allows for the use of adhesives that are approved
for use in the transport of food.
[0042] Referring now to FIG. 8, a side view of a preferred
embodiment of a pallet is shown. FIG. 8 shows a stringer 30, deck
boards 10 and lead deck boards 90. The lead deck board 90 has a
height 90a and a width 90b and opposing surfaces 99, 100. The
stringer 30 comprises notches 92. The notches 92 can have a first
surface 94 and a second surface 96. The notches have a depth 92a
and a width 92b. Preferably, the width 90b of the lead deck board
90 is substantially similar to the width 92b of the notches 92 so
that the lead deck board 90 can be disposed in the notch 92.
Preferably, the height 90a of the lead deck board 90 can be
substantially similar to the sum of the width 18 of the deck board
10 and the depth 92a of the notch so that, when disposed in the
notch 92, surface 100 can be substantially planar to surface 14 of
the deck boards 10. In this embodiment, the lead deck board 90 is
able to withstand a greater shearing force because the connection
between the lead deck board 90 and stringer 30 receives lateral
support from the second surface 96 of the stringer 30. The lead
deck board 90 can be connected to the stringer 30 with wooden
dowels 50 and adhesive.
[0043] In another embodiment, the notches 92 can have an angled
second surface 96 (angle not shown). Preferably, a corresponding
surface 98 of the lead deck board 90 is angled complimentary to the
angled second surface 96 to form, e.g., a dovetail configuration
(not shown). Preferably, the deck boards and lead deck boards are
connected to the stringer 30 using a wooden dowel 50 and adhesive,
as described hereinabove.
[0044] In a preferred embodiment, the pallet described herein
consists essentially of wood and adhesive. In the most preferred
embodiment, the pallet consists of wood and adhesive. The use of a
wooden dowel 50 and wooden stringers 30 and deck boards 10, along
with adhesive, can, through construction, create a pallet that
exceeds industry requirements for static strength, stiffness, and
resistance to rough handling.
[0045] Further, the pallet described herein can be substantially
lighter than standard pallets that employ nails or other metal
fasteners. First, the use of wooden dowels inserted into bores or
openings instead of nails creates less weight. The weight of the
dowel 50 being inserted is offset by the amount of wood drilled out
of the deck boards 10 and stringers 30. With the use of nails,
there is no offset. With the use of a large number of nails in
typical pallets (sometimes over one hundred for a used pallet),
this weight difference can become substantial. Second, the pallet
described herein can be made with kiln dried wood, which is lighter
than wet or green wood. Typical pallets are made of wet or green
wood because hammering in nails in dry wood can cause damage to the
wood, such as checking, and result in a damaged or weakened pallet.
Through the use of the dowel 50, the pallet described herein can be
constructed of wood that is kiln dried. Preferably, the wood is
less than 15% moisture and more preferably between 9 and 12%
moisture. The pallet described herein can be substantially lighter
than typical patents, making them less likely to cause injury to
workers during transport, and also yielding substantial savings in
fuel economy during transport.
[0046] It is believed that the pallet described herein can be
constructed so that it meets industry requirements for a rated load
of 2800-pounds that is less than sixty pounds. Preferably, such a
pallet will be between fifty three and fifty eight pounds. More
preferably, such a patent will be less than fifty three pounds. In
contrast, the typical wooden pallet can weigh from seventy to
eighty pounds.
[0047] The construction of a pallet of essentially all kiln dried
wood and adhesive creates further advantages. A significant
advantage is that the pallet is less likely to interfere with RFID.
As seen in FIGS. 6 and 8, an RFID device 110 can be attached to the
pallet. Preferably, the RFID device 110 is attached to an inside
surface 34 or 35 of the middle stringer 30 or one of the outside
stringers 30. A warehouse (not shown) can have an RFID reader (not
shown) near a dock door. When the pallet described herein, with the
attached RFID device 110, enters the warehouse, the RFID reader
will can read the RFID device 110. RFID readers can have difficulty
reading RFID devices which are near liquid, which absorbs RF
signals. The pallet described herein can be constructed of dried
wood, lessening the amount of RF signal absorption and potentially
allowing for higher read rate accuracy. Further, the pallet
described herein is preferably constructed without metal. Metal can
prevent RF readers from working properly. The pallet described
therein is therefore likely to yield higher read rate accuracy.
[0048] The preferred lack of metal also allows for the pallet to be
subjected to microwave sterilization. This potentially results in a
pallet that does not, for example, transport alien organisms or
animals from one region to another.
[0049] The present invention is not limited to their particular
details of the method depicted, and other modifications and
applications are contemplated. Certain other changes may be made in
the above-described method without departing from the true spirit
and scope of the invention herein involved. For example, the
present method may be utilized with other styles of pallets, which
have different formations of stringers, panel boards, or like
members. It is intended, therefore, that the subject matter in the
above depiction shall be interpreted as illustrative and not in a
limiting sense.
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