U.S. patent application number 13/575744 was filed with the patent office on 2013-02-07 for pallets for the handling of goods, processes for manufacturing pallets and methods of using pallets in the handling of goods.
The applicant listed for this patent is Pieter W. Du Toit, Karl-Heinz Schmitt. Invention is credited to Pieter W. Du Toit, Karl-Heinz Schmitt.
Application Number | 20130032507 13/575744 |
Document ID | / |
Family ID | 43929014 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130032507 |
Kind Code |
A1 |
Du Toit; Pieter W. ; et
al. |
February 7, 2013 |
PALLETS FOR THE HANDLING OF GOODS, PROCESSES FOR MANUFACTURING
PALLETS AND METHODS OF USING PALLETS IN THE HANDLING OF GOODS
Abstract
Processes, a pallet (10) and a pallet system are provided for
the handling of goods. The pallet (10) includes a main body (12)
defining a load deck (16) and feet (18) and the main body (12) is
suitable to be used as a pallet for applications such as light
duty, one-way transport of goods. The pallet (10) further includes
a bottom accessory (14) that can be attached to the feet (18) of
the main body (12) to form beams (44,46) extending between the feet
(18) to convert the main body (12) into pallet (10) that is
suitable for use in heavy duty applications such as in pallet
pools. The main body (12) and bottom accessory (14) are each
configured to allow them to be nested, when not attached to each
other. The processes of the invention include using the main body
(12) to transport goods from manufacturers and then attaching the
bottom accessory (14) to the main body (12) to form a pallet (10)
for use in a pallet pool. The pallet system includes a variety of
attachments that can be attached to the main body (12) and/or the
accessory (14) and can be removed, as necessary.
Inventors: |
Du Toit; Pieter W.;
(Southern Paarl, ZA) ; Schmitt; Karl-Heinz;
(Benoni, ZA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Du Toit; Pieter W.
Schmitt; Karl-Heinz |
Southern Paarl
Benoni |
|
ZA
ZA |
|
|
Family ID: |
43929014 |
Appl. No.: |
13/575744 |
Filed: |
January 28, 2011 |
PCT Filed: |
January 28, 2011 |
PCT NO: |
PCT/IB2011/050380 |
371 Date: |
October 19, 2012 |
Current U.S.
Class: |
206/599 ;
108/53.3; 108/57.25 |
Current CPC
Class: |
B65D 2519/00363
20130101; B65D 2519/00308 20130101; B65D 2519/0086 20130101; B65D
2519/00572 20130101; B65D 2519/0096 20130101; B65D 2519/00293
20130101; B65D 2519/00318 20130101; B65D 2519/00288 20130101; B65D
19/0012 20130101; B65D 2519/00069 20130101; B65D 2519/00273
20130101; B65D 2519/00333 20130101; B65D 2519/00567 20130101; B65D
2519/00522 20130101; B65D 2519/00338 20130101; B65D 2519/00373
20130101; B65D 2519/00412 20130101; B65D 2519/00407 20130101; B65D
19/0018 20130101; B65D 2519/0094 20130101; B65D 2519/0099 20130101;
B65D 2519/00034 20130101; B65D 2203/10 20130101 |
Class at
Publication: |
206/599 ;
108/53.3; 108/57.25 |
International
Class: |
B65D 19/00 20060101
B65D019/00; B65D 19/38 20060101 B65D019/38; B65D 19/40 20060101
B65D019/40; B65D 19/26 20060101 B65D019/26; B65D 19/06 20060101
B65D019/06; B65D 19/24 20060101 B65D019/24; B65D 19/42 20060101
B65D019/42 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 28, 2010 |
ZA |
2010/00656 |
Apr 6, 2010 |
ZA |
2010/02377 |
Apr 9, 2010 |
ZA |
2010/02486 |
Claims
1-57. (canceled)
58. A pallet comprising a load deck with a generally planar load
surface, said load deck defining a plurality of cavities and webs
extending at least partly between adjacent cavities, said load deck
having dimensions of about 40.times.48 inches, and a plurality of
spaced-apart feet protruding from the load deck on a side that is
opposite from the load surface, said feet being hollow and
tapering, such that the feet of an upper such pallet are at partly
receivable inside the feet of a lower such pallet in a nesting
manner; wherein said pallet: (a) deflects by less than 20 mm when
supported on opposing edges under a load of 2800 pounds; (b) Is
made of fibre reinforced material; and (c) weighs less than 40
pounds
59. A pallet as claimed in claim 58, wherein said pallet weighs
less than 30 pounds.
60. A pallet as claimed in claim 58, wherein said pallet includes
an accessory extending between at least some the pallet's feet
61. A pallet as claimed in claim 58, wherein each of said webs of
the load deck has a cross sectional profile with a neutral axis, at
least some of the webs extend at an obtuse angle relative to the
load deck, and at least some of said webs define apertures between
an upper edge and a lower edge of each such web, such that said
apertures are in the vicinity of the neutral axis of the web.
62. A pallet as claimed in claim 61, wherein the load deck defines
an under surface that extends generally parallel to the load
surface and the load deck includes flanges extending from upper
edges of the webs, generally co-planar along the load surface; and
flanges extending from lower edges of the webs, generally co-planar
along the under surface; said flanges defining apertures in the
load deck and the under surface, between adjacent webs.
63. A pallet as claimed in claim 62, wherein at least some of said
webs have one of said flanges extending from the upper edge of said
web in one direction and one of said flanges extending from the
lower edge of said web in an opposite direction.
64. A pallet as claimed in claim 58, wherein said pallet includes
inserts that are shaped to fit removably inside the hollow feet of
the lower main body.
65. A pallet as claimed in claim 58, which includes an accessory
and wherein at least each corner foot defines at least one first
attachment formation that is attachable to the accessory of the
pallet, such that the accessory extends at least between the
attachment formations of the corner feet, said accessory including
a plurality of second attachment formations that are attachable to
the first attachment formations on at least some of the feet and
the accessory defining a plurality of accessory recesses in which
the feet are receivable, at least in part, wherein said first
attachment formations are defined at the bottoms of the feet and
the second attachment formations are disposed inside the accessory
recesses, where they are protected against damage.
66. A pallet as claimed in claim 65, wherein the accessory defines
at least one beam extending between at least some of the feet when
the accessory is attached to the feet.
67. A pallet as claimed in claim 65, wherein feet recesses are
defined in undersides of the feet and accessory protuberances are
defined on the accessory, the accessory protuberances being
receivable in the feet recesses, at least in part and each of the
accessory protuberances is of a hollow construction with tapering
walls, such that the accessory protuberances of one such accessory
are partly receivable inside the accessory protuberances of another
such accessory in a nesting manner.
68. A pallet as claimed in any one of claim 65, wherein the
attachment formations are releasable.
69. A pallet as claimed in claim 68, wherein the attachment
formations include clip formations and wherein the pallet defines
release apertures through which a release element can be inserted
to release the clip formations.
70. A pallet comprising a load deck with a generally planar load
surface and a plurality of spaced-apart feet protruding from the
load deck on a side that is opposite from the load surface, said
feet being hollow and tapering such that the feet of an upper such
pallet are partly receivable inside the feet of a lower such pallet
in a nesting manner, wherein said pallet includes inserts that are
shaped to fit removably inside the hollow feet of the lower
pallet
71. A pallet as claimed in claims 70, wherein said pallet includes
a plurality of wheels that are releasably attachable to said
pallet.
72. A pallet as claimed in claim 71, wherein each of said wheels is
rotatably supported in an adaptor, which is attachable to said
pallet in a clipping manner.
73. A load deck with a generally planar load surface, said load
deck having an open construction defining a plurality of cavities
and webs extending at least partly between adjacent cavities, each
web having a cross sectional profile with a neutral axis; wherein
at least some of the webs extend at an obtuse angle relative to the
load deck and at least some of said webs define apertures between
an upper edge and a lower edge of each such web, such that said
apertures are in the vicinity of the neutral axis of the web.
74. A load deck as claimed in claim 73, wherein the load deck
defines an under surface that extends generally parallel to the
load surface and the load deck includes flanges extending from
upper edges of the webs, generally co-planar along the load
surface; and flanges extending from lower edges of the webs,
generally co-planar along the under surface; said flanges defining
apertures in the load deck and the under surface, between adjacent
webs.
75. A load deck as claimed in claim 74, wherein at least some of
said webs have one of said flanges extending from the upper edge of
said web in one direction and one of said flanges extending from
the lower edge of said web in an opposite direction.
76. A pallet comprising a load deck with a generally planar load
surface and a plurality of spaced-apart feet protruding from the
load deck on a side that is opposite from the load surface, said
feet being hollow and tapering, such that the feet of an upper such
pallet are at partly receivable inside the feet of a lower such
pallet in a nesting manner; wherein releasable attachment
formations are defined on the said load deck and feet, to which
accessories are removably attachable.
77. A pallet as claimed in claim 76, wherein said pallet includes
at least one edge insert that is releasably attachable to said edge
with grip formations gripping the edge, said edge insert including
a protuberance that protrudes above said load deck.
78. A pallet as claimed in claim 77, wherein said pallet includes
at least one deck extension accessory that is releasably attachable
to said edge with grip formations gripping the edge, said deck
extension accessory extending in alignment with the load deck, from
the edge of the load deck, when attached to said edge.
79. A pallet as claimed in claim 76, wherein said pallet includes:
a plurality of walls, each wall defining a first edge, which forms
a top edge in use, a second edge, opposite from the first edge and
which forms a bottom edge in use, and third and fourth edges that
form lateral edges in use; pivotal attachment means holding the
lateral edges of adjacent walls together in a pivoting side-by-side
arrangement, with a pivot axis extending generally along the
attached lateral edges; and wall attachment formations disposed
along the bottom edges of the walls, said wall attachment
formations being releasably attachable to the releasable attachment
formations of the load deck.
80. A pallet as claimed in any one of claim 76, wherein said
releasable attachment formations include attachment formations
disposed on the undersides of the feet of the pallet and said
pallet includes a plurality of wheels that are releasably
attachable to said attachment formations.
81. A pallet as claimed in claim 80, wherein each of said wheels is
rotatably supported in an adaptor, which is attachable to said
pallet in a clipping manner.
82. A pallet as claimed in any one of claim 76, wherein said pallet
includes inserts that are shaped to fit removably inside the hollow
feet of the pallet
83. A pallet comprising a load deck with a generally planar load
surface and a plurality of spaced-apart feet protruding from the
load deck on a side that is opposite from the load surface wherein
said pallet includes at least one sleeve that can be attached to a
foot of pallet by extending around at least part of the foot.
84. A pallet comprising a load deck with a generally planar load
surface and a plurality of spaced-apart feet that can protrude from
the load deck on a side that is opposite from the load surface
wherein said feet are manufactured separately from the load deck
and are attachable to the load deck and optionally to an
accessory.
85. A pallet as claimed in claim 84, wherein said feet are
releasably attachable to the load deck.
86. A pallet as claimed in claim 84, wherein said feet are made of
different material from the load deck.
Description
FIELD OF THE INVENTION
[0001] This invention relates to pallets for the handling of goods
(including transport and storage of the goods) and extends to
methods of manufacturing the pallets and methods of using the
pallets in the handling of goods.
BACKGROUND TO THE INVENTION
[0002] Pallets are used on a very large scale in the handling of
goods and efforts are made continually to reduce the cost of
pallets, improve their mechanical properties, extend their service
life, etc.
[0003] There are various specifications that pallets need to meet
for various applications, but some of the divisions that can be
used to classify patents, include whether or not pallets are
returnable (e.g. to a supplier who supplies goods on the pallet),
stackable (i.e. loaded pallets resting on the loads of pallets
below) rack-able (i.e. pallets can slide into racks and support
loads for extended periods), light weight, heavy duty. Depending on
which of these properties are required in a pallet (in addition to
common requirements such as cost, strength, repair-ability, etc),
the design of a pallet is typically a compromise between different
attributes and there is a continuous need to improve the overall
properties of pallets while inhibiting compromises.
[0004] One of the problems experienced in the pallet industry, is
that suppliers of bulk products, e.g. polymer manufacturers, need
to transport their products to customers on pallets, but they do
not wish to be saddled with the task of retrieving pallets after
products have been delivered. They see pallets as a consumable
packaging cost. They thus typically supply products on
non-returnable pallets and in order to keep costs to a minimum, the
pallets are made light in weight (typically about 60 lbs) and with
only sufficient strength to carry the load of the goods being
loaded. The pallets are typically not made durable enough and/or do
not have the mechanical strength to allow them to be used in other
applications, such as heavier loading, stacking, racking, or the
like on a continuous basis. These light-weight non-returnable one
way pallets (referred to in the art as "export pallets", "white
pallets" or "one way pallets") are thus typically discarded at
their destinations, causing wastage in the cost of the pallets and
causing a burden on the environment.
[0005] Most export pallets are presently being made of wood, but in
many countries, suitable timber is not available for making pallets
and the timber pallets either have to be imported at great expense,
or the timber needs to be imported at similar, although slightly
lower, expense and the pallets need to be manufactured, burdening
manufacturers of products with costs and/or effort. Further, apart
from the obvious environmental impact of deforestation caused by
the supply of timber for pallets, the transport of timber pallets
(or timber for pallets) increases gas emissions.
[0006] Once export pallets reach their destinations, they are
typically discarded, because they are not suitable for use as
so-called "pool pallets" that are made for use in different
applications such as stacking and racking and are re-used
repeatedly. The export pallets thus cause further environmental
burden because they are either discarded directly as solid waste,
or they have to be dismantled (depending on the type of pallet) and
their materials disposed of in a suitable manner, such as
incineration.
[0007] In many countries, "disposal fees" are levied before a
timber pallet is allowed to enter the country and/or the pallet
needs to be fumigated, heat treated or the like.
[0008] Another problem experienced in the pallet industry is the
need to transport unloaded pallets cost effectively--whether during
the supply of pallets to a user, the retrieval of pallets, or the
like. The main problem in this respect is that pallets are bulky by
their nature (which is to provide an elevated load platform with
space underneath for lifting forks) and unloaded pallets thus
occupy large volumes.
[0009] Another problem is one of labour because wooden pallet loads
received in one country may need to be repacked on a different size
pallet that fits the automated warehouse requirements.
[0010] Another problem experienced in the pallet industry is the
need to repair pallets that become damaged. In some cases, it is
cost-effective to repair pallets, typically by removing broken
parts and replacing them with new parts. It is for instance common
practice to remove broken slats in wooden pallets and replace them.
However, in many instances, the parts of pallets cannot be
separated easily and they are simply discarded when damaged, or the
connections between parts of pallets are damaged easily and the
pallets cannot be re-assembled with sufficient strength.
[0011] Yet another problem experienced in the pallet industry is
that the attachment formations of multiple component pallets break
during extended use of the pallets, because they are exposed to
various loads such as impacts from lifting forks, impacts while the
empty pallets are handled, etc.
[0012] Yet another problem experienced in the pallet industry is
that there are different standard pallet sizes that are used for
different types of goods, load weights, storing configurations
(e.g. with or without stacking and/or racking), etc. The space
constraints in different areas where the pallets need to be stored
vary and as a result, pallet sizes that are suitable for one
application, e.g. for handling fast-moving consumer goods are not
necessarily of a size that allows optimal use of the floor space
available in a standard freight container or an automated warehouse
racking system.
[0013] Some export pallets are made with tapered feet that allow a
number of the pallets to nest on top of each other and thus to save
space when not loaded. However, the hollow feet of these pallets
create large discontinuities in their load decks that detract from
the structural strength and stability (stiffness) in the regions of
the feet.
[0014] In some moulded pallets, ribs are provided in the pallet's
structure, especially under its load deck, to improve the strength
of the pallet, especially its bending strength.
[0015] However, in order to de-mould the pallet after moulding it,
the moulds have to be made with draft angles and the result is that
the ribs have tapered cross-sectional profiles that are wider at
one end than the opposite end. These tapered profiles do not
provide optimal strength, require additional material to be used in
the pallet and thus add to the cost of the pallets.
[0016] There is often a requirement that pallets on which goods are
transported, should be capable of being stacked and/or racked at
the location where they are received, and accordingly, instead of
the pallets on which the goods are despatched being designed only
to serve the purposes of handling and bearing the loads of the
goods during the journey, the pallets also need to be designed to
have the additional properties allowing them to be used in
warehousing systems or the like. The result is that goods that can
be transported on light duty pallets are transported on heavy duty
pallets, which cost more to manufacture and which have increased
transport costs both while empty (before and/or use) and when
loaded.
[0017] There is often a need for storage bins that can be lifted
with the forks of conventional lifting devices (e.g. fork lift
trucks, jacks, automated warehouse systems, or the like), but that
has upright walls to define a bin in which goods can be held. Bins
of this type are in use, which effectively comprise conventional
timber pallets with upright timber walls. These pallet bins are
heavy, expensive and environmentally unfriendly because of their
timber construction and because they occupy very large storage
volumes when they are empty. Similar pallet bins have been made
from plastics materials, but they suffer from the same
disadvantages--they need to be heavily engineered to be strong
enough to withstand loads and are thus heavy and expensive and
while they do not cause deforestation, their weight causes an
increase on the energy requirements when transporting these pallet
bins.
[0018] In an attempt to reduce the excessive space requirements
when storing or transporting the pallet bins described above,
partly or wholly collapsible pallet bins have been developed with
walls that are removably attachable to each other, e.g. with clips
and/or walls that are removably attachable to the pallet. The
mechanisms for attaching these walls to one another typically
require clips that are easily lost or parts that are integrally
formed with the walls, that need to clip, slide, etc. together, but
these mechanisms are prone to damage or loss of accessories and as
a result, existing collapsible pallet bins are unsatisfactory.
[0019] In order to make optimal use of available storage space,
pallet bins often need to be stacked, with upper pallet bins
supported by the walls of lower pallet bins. In order to provide
sufficient strength in the walls of the pallet bins to carry the
weight of the pallet bins above them, the walls are made with a
heavy, durable construction--with the disadvantages mentioned
above. Pallet bins with collapsible walls are either even heavier
or lack the strength to allow stacking.
[0020] The present invention seeks to addressing the shortfalls
mentioned above, including providing cost effective, light weight
pallets with good load carrying abilities, providing convenient and
cost effective use of pallets by reducing the weight of pallets
during transportation, while maintaining the structural properties
of the pallets to bear static and dynamic loads, to be capable of
stacking and racking, and the like, and to provide a pallet system
including detachable fittings that can be added to pallets.
SUMMARY OF THE INVENTION
[0021] According to a first aspect of the present invention there
is provided a pallet comprising a main body, said main body
comprising: [0022] a load deck with a generally planar load
surface; and [0023] a plurality of spaced-apart feet protruding
from the load deck on a side that is opposite from the load
surface, said feet including at least one corner foot in each of
four corner regions of the body; [0024] wherein [0025] said load
deck has an open construction defining a plurality of cavities and
webs extending at least partly between adjacent cavities; [0026]
said feet being hollow and tapering, such that the feet of one such
body are partly receivable inside the feet of another such body in
a nesting manner; [0027] said pallet having a weight of less than
40 pounds, preferably less than 30 pounds; and [0028] said pallet
being made of fibre reinforced material.
[0029] According to another aspect of the present invention there
is provided a pallet comprising a main body, said main body
comprising: [0030] a load deck with a generally planar load
surface, said load deck defining a plurality of cavities that are
each open on at least one side and said load deck including a
plurality of webs extending at least partly between adjacent
cavities; and [0031] a plurality of spaced-apart feet protruding
from the load deck on a side that is opposite from the load
surface, said feet including at least one corner foot in each of
four corner regions of the body, the feet serving as supports to
keep the load deck elevated and the spaces between the feet
providing access for inserting lifting devices underneath the load
deck; [0032] wherein at least some of the webs extend at an obtuse
angle relative to the load deck and at least some of said webs
define apertures between an upper edge and a lower edge of each
such web.
[0033] The term "elevated" means that the load deck is at a higher
elevation than a surface on which the pallet is supported, when in
an upright orientation. The construction of a part of the pallet
with a plurality of cavities that are open on at least one side, is
referred to herein as an "open" structure.
[0034] The load deck may have a depth of more than 20 mm,
preferably about 36 mm.
[0035] The load deck may include flanges extending generally
co-planar with the load surface and the flanges may extend from
upper edges of the webs of the load deck and define apertures in
the load deck, between adjacent webs, in which inserts may be
receivable.
[0036] The load deck may define an under surface that extends
generally parallel to the load surface, between the feet and the
load deck may include flanges extending generally co-planar with
the under surface. The flanges extend from lower edges of the webs
of the load deck and may define apertures in the load deck, between
adjacent webs, which could assist in withstanding impact from
lifting devices such as forks.
[0037] The main body may be made of a fibre reinforced polymeric
material and may weigh less than 44 lbs and in one preferred
embodiment, the load surface may have dimensions of about
40.times.48 inches as the pallet may weigh less than 35 lbs. In
addition to the fibre reinforcement, the polymeric material may
include supporting additives.
[0038] Each of the feet may be of a hollow construction with
tapering walls, such that the feet of one such body are partly
receivable inside the feet of another such body in a nesting
manner.
[0039] The pallet may further include an accessory and one or more
of the corner feet may define one or more first attachment
formation that is attachable to the accessory of the pallet, such
that the accessory extends at least between the attachment
formations of the corner feet, e.g. in the form of a cruciform,
picture frame, or both.
[0040] According to another aspect of the present invention there
is provided a pallet comprising a main body, said main body
comprising:
a load deck with a generally planar load surface, said load deck
defining a plurality of cavities that are each open on at least one
side with webs extending at least partly between adjacent cavities;
and a plurality of spaced-apart feet protruding from the load deck
on a side that is opposite from the load surface, said feet
including at least one corner foot in each of four corner regions
of the body, the feet serving as supports to keep the load deck
elevated and the spaces between the feet providing access for
inserting lifting devices underneath the load deck, each of said
feet being of a hollow construction with tapering walls, such that
the feet of one such body are partly receivable inside the feet of
another such body in a nesting manner; wherein each foot defines at
least one tapered recess extending from the bottom of the foot,
towards the load deck.
[0041] One or more of the recesses may extend from the bottom of
its associated foot to the vicinity of the load deck and the foot
may includes a structure, e.g. a structure in the form of a cross
member, that is generally aligned with the load deck and that spans
the recess.
[0042] The body may be dimensioned such that, when an upper such
body is nested on top of a lower such a body, the underside of the
structures spanning the load recesses of the upper body's feet,
rests in abutment on the load surface of the lower body, such that
the abutment between said structures of the upper and lower bodies
prevent the feet of the upper body from entering the insides of the
feet of the lower body beyond a predetermined extent.
[0043] The pallet may include nine feet or more, including the four
corner feet, and each of the corner feet may have at least one of
said recesses that divides the corner foot into at least two
pillars. Preferably, each of the nine feet may have such a recess
that divides the foot into two or more pillars, such that the
pallet has at least eighteen of these pillars and more preferably,
each of the nine feet has such a recess that divides the foot into
four pillars, such that the pallet has thirty six of these
pillars.
[0044] According to a further aspect of the present invention there
is provided a pallet comprising a main body and an accessory, the
main body defining an open load deck with a plurality of cavities
that are each open on at least one side, said load deck defining a
generally planar load surface and a plurality of spaced-apart feet
protruding from the body on a side that is opposite from the load
surface, said feet including at least one corner foot in each of
four corner regions of the body, the feet serving as supports to
keep the load deck elevated and the spaces between the feet
providing access for inserting lifting devices underneath the load
deck; wherein each of the feet is of a hollow construction with
tapering walls, such that the feet of one such body are partly
receivable inside the feet of another such body in a nesting manner
and wherein each corner foot defines at least one first attachment
formation that is attachable to the accessory of the pallet, such
that the accessory extends at least between the attachment
formations of the corner feet;
wherein said accessory is also of an open construction, defining a
plurality of cavities that are each open on at least one side.
[0045] Feet recesses may be defined in undersides of the feet and
accessory protuberances may be defined on the accessory so that the
accessory protuberances are receivable in the feet recesses, at
least in part.
[0046] Each of the accessory protuberances may be of a hollow
construction with tapering walls, such that the accessory
protuberances of one such accessory are partly receivable inside
the accessory protuberances of another such accessory in a nesting
manner.
[0047] The accessory may include a plurality of second attachment
formations that are attachable to the first attachment formations
on at least some of the feet and the accessory may define a
plurality of accessory recesses in which the feet are receivable,
at least in part, with the second attachment formations being
disposed inside the accessory recesses, where they are protected
against damage.
[0048] The accessory may define at least one beam extending between
two or more of the feet when the accessory is attached to the feet
and the beam may be of an open construction defining a plurality of
cavities that are each open on at least one side.
[0049] The accessory may define at least one beam extending between
two or more of the feet when the accessory is attached to the feet,
and the accessory may be dimensioned such that, when an upper such
accessory is nested on top of a lower such accessory, the
undersides of the upper accessory's beams rest in abutment on the
beams of the lower accessory, such that the abutment between the
beams of the upper and lower accessories prevent the upper body
from entering the accessory recesses of the lower accessory beyond
a predetermined extent.
[0050] The attachment formations of the pallet may be releasable
and may include clip formations and the pallet may define release
apertures through which a release element can be inserted to
release the clip formations.
[0051] The pallet may define a plurality of apertures in a top
surface of its load deck, in an underside of its load deck, on
upper sides of the beams, and/or on undersides of the beams, in
which inserts are receivable. The pallet may include a plurality of
these inserts that are receivable in the apertures, each insert
being of a slip resistant material.
[0052] The pallet may include at least one corner sleeve that can
be attached to a foot of the main body by extending around at least
part of the foot, the corner sleeve being held captive on the foot
between the accessory and the load deck, when the accessory is
attached to the first attachment formations.
[0053] The pallet's load deck may include a solid peripheral edge
adjacent at least some of its cavities and an edge insert or a deck
extension accessory may be releasably attachable to the edge, with
grip formations such as hook formations and/or clip formations
gripping the edge. The edge insert may include a protuberance or
ridge that protrudes above the load deck and the deck extension
accessory may extend in alignment with the load deck, from the edge
of the load deck.
[0054] The pallet may include a plurality of wheels that are
releasably attachable to the pallet and each of the wheels may be
rotatably supported in an adaptor, which is attachable to the
pallet in a clipping manner, e.g. the adaptor may be attachable to
the underside of a foot of the main body, or to the accessory.
[0055] According to a further aspect of the present invention there
is provided apparatus for the handling of goods, said apparatus
comprising: [0056] a pallet body defining a load deck and feet
protruding from an underside of the load deck; [0057] a plurality
of walls, each wall defining a first edge, which forms a top edge
in use, a second edge, opposite from the first edge and which forms
a bottom edge in use, and third and fourth edges that form lateral
edges in use; [0058] pivotal attachment means holding the lateral
edges of adjacent walls together in a pivoting side-by-side
arrangement, with a pivot axis extending generally along the
attached lateral edges; [0059] deck attachment formations disposed
along the periphery of the load deck; and [0060] wall attachment
formations disposed along the bottom edges of the walls, said wall
attachment formations being releasably receivable in the deck
attachment formations.
[0061] The load deck of the pallet body may be rectangular and the
apparatus may include six walls, including two rigid walls that are
configured to extend along the length of opposing edges of the load
deck when attached to the load deck, with the four remaining walls
forming two pairs, each pair being configured to extend along the
length of one of the load deck's edges, between the rigid walls.
The walls may include six corners where the side edges of the
adjacent walls are pivotally connected together by the pivot
attachment means and the pivot attachment means may be configured
to allow each of the pairs of walls to pivot inwardly, towards the
other of said pairs of walls.
[0062] Each wall may be of a construction comprising an array of
webs defining cavities between them, each cavity having a large
opening on one side of the wall and a shape that tapers towards a
smaller opening on the opposing side of the wall, and adjacent
cavities being disposed with their large openings on opposing sides
of the wall. Each cavity may have a flange that extends around its
small opening and that is integrally formed with the webs.
[0063] The deck attachment formations may include a plurality of
recesses defined in the load deck and the wall attachment
formations may include protuberances extending from the bottom edge
of the wall, said protuberances being receivable the recesses of
the deck attachment formations, preferably in a clipping manner.
Instead or in addition, the deck attachment formations may include
an edge of the load deck and the wall attachment formations may
include clip formations that can grip the edge of the load
deck.
[0064] At least some of the walls may include positioning
formations on their upper edges, that are configured to receive the
underside of the a pallet body when stacked above the walls.
[0065] The pallet may include a lid that is pivotably attached to
one of the walls.
[0066] According to yet another aspect of the present invention
there is provided a process for manufacturing a pallet with a load
deck, said process including:
closing two parts of a two-part mould to form a mould cavity;
injecting mouldable material into the mould cavity; allowing the
mouldable material to solidify to form the pallet; and de-moulding
the pallet; wherein the pallet includes a plurality of webs in its
load deck, each web being oriented at an obtuse angle relative to
the load deck, and wherein the two parts of the two-part mould abut
in the vicinity of a neutral axis of at least some of said webs,
when the mould is closed, to define an aperture in the web in the
vicinity of its neutral axis.
[0067] The mouldable material may be a fibre reinforced polymeric
material, preferably with supporting additives.
[0068] According to a further aspect of the present invention there
is provided a method of using pallets, each of said pallets
comprising a pallet body defining a load deck and feet protruding
from an underside of the load deck, said method comprising: [0069]
transporting a first such a pallet body from a first location to a
second location; [0070] keeping a number of accessories at said
second location, each such accessory being attachable to the
underside of the feet of such a pallet body, to extend between at
least some of the feet of the pallet body and provide structural
support to the pallet body; [0071] supporting said first pallet
body on such an accessory at the second location; [0072] using said
first pallet body and its supporting accessory at the second
location; [0073] removing the first pallet body from its supporting
accessory; and [0074] despatching the first pallet body from the
second location.
[0075] The term "supported" is not intended to be limited to the
bearing of weight, i.e. it does not merely refer to "carrying", but
has a wider meaning of imparting structural strength and/or
stiffness.
[0076] The first pallet body may be supported on its supporting
accessory by attaching the accessory to the feet of the first
pallet body, or the accessory may be attached to a second such
pallet body and the first pallet body may be received on top of the
second pallet body while at the second location, to be supported at
least in part, by the accessory attached to the second pallet body.
The first pallet body and the second pallet body may be nestable,
and the method may include nesting the feet of the first pallet
body in the second pallet body while at the second location, to
hold the first pallet body in position on the second pallet
body.
[0077] At least some of the accessories may have wheels and the
method may include moving the pallet body and its supporting
accessory at the second location, by rolling the accessory on its
wheels.
[0078] The term "wheel" is intended to include any variation of
rolling element support and thus includes rollers, castors, or the
like.
[0079] According to another aspect of the present invention there
is provided a method of using pallets, each of said pallets
comprising a pallet body defining a load deck and feet protruding
from an underside of the load deck, said method comprising: [0080]
transporting a first such a pallet body from a first location to a
second location; [0081] keeping a number of wheeled pallet bodies
at said second location, each such wheeled pallet body comprising a
pallet body defining a load deck and feet protruding from an
underside of the load deck, with wheels attached to the undersides
of at least some of its feet; [0082] supporting said first pallet
body on such a wheeled pallet body at the second location; [0083]
using said first pallet body and its supporting wheeled pallet body
at the second location; [0084] removing the first pallet body from
its supporting wheeled pallet body; and [0085] despatching the
first pallet body from the second location.
[0086] The first pallet body and the wheeled pallet body may be
nestable, and the method may include nesting the feet of the first
pallet body in the wheeled pallet body while at the second
location, to hold the first pallet body in position on the wheeled
pallet body. The first pallet body may be releasably attached to
the wheeled pallet body.
[0087] According to a further aspect of the present invention there
is provided a method of using pallets, each of said pallets
comprising a pallet body defining a load deck and feet protruding
from an underside of the load deck, said method comprising: [0088]
transporting a first such a pallet body from a first location to a
second location; [0089] keeping a number of accessories at said
second location, each such accessory being attachable to the
underside of the feet of such a pallet body, to extend between at
least some of the feet of the pallet body and provide structural
support to the pallet body, with wheels attached to the underside
of at the accessory; [0090] supporting said first pallet body on
such a wheeled accessory at the second location; [0091] using said
first pallet body and its supporting wheeled accessory at the
second location; [0092] removing the first pallet body from its
supporting wheeled accessory; and [0093] despatching the first
pallet body from the second location.
[0094] The first pallet body may be nestable in a second pallet
body defining a load deck and feet protruding from an underside of
the load deck, with the feet of the first pallet body being
receivable inside the feet of the second pallet body in a nesting
manner, and the method may include attaching the second pallet body
to the wheeled accessory and supporting the first pallet body by
receiving it on top of the second pallet body, in nesting
fashion.
[0095] The method may include transporting and/or storing goods on
the first pallet body during transportation of the first pallet
body from the first location to the second location, during use of
the first pallet body at the second location, and/or during
despatch of the first pallet body from the second location.
[0096] According to yet a further aspect of the present invention
there is provided a method for providing pallets for the handling
of goods, said method comprising: [0097] providing a pallet body
defining an open load deck defining a plurality of cavities that
are each open on at least one side, said load deck having a
generally planar load surface and a plurality of spaced-apart feet
protruding from the body on a side that is opposite from the load
surface, said feet including at least one corner foot in each of
four corner regions of the body, the feet serving as supports to
keep the load deck elevated and the spaces between the feet
providing access for inserting lifting devices underneath the load
deck; [0098] loading goods onto the load deck of the pallet body;
[0099] transporting the pallet body with the goods loaded on top of
it; and [0100] attaching an accessory to the feet of the pallet
body such that the accessory extends at least between the four
corner feet in a manner such that the accessory is spaced from the
load deck.
[0101] The load deck of the pallet body may include a plurality of
webs extending at least partly between adjacent cavities, at least
some of the webs extending at an obtuse angle relative to the load
deck and at least some of these webs defining apertures between an
upper edge and a lower edge of each such web.
[0102] The method may include supporting the pallet on opposing
sides in a racking system, after attaching the accessory to the
feet of the pallet.
[0103] The method may include off-loading the goods before
attaching the accessory to the feet of the pallet body.
[0104] The method may include an additional step of releasing the
attachment of the accessory from the feet of the pallet body and
may further include re-attaching the accessory to the feet of the
pallet body.
[0105] Each of the pallet body's feet may be of a hollow
construction with tapering walls and the method may include the
step of transporting a plurality of the pallet bodies in a nesting
arrangement, with the feet of one such body partly received inside
the feet of another such body in a nesting manner, before loading
the pallet body with goods.
[0106] Each of the pallet body's feet may be of a hollow
construction with tapering walls and the method may include the
step of transporting a plurality of the pallet bodies in a nesting
arrangement, with the feet of one such body partly received inside
the feet of another such body in a nesting manner, after the goods
have been off-loaded and before the accessories are attached to the
main bodies.
[0107] The goods to be transported on the pallet body may include a
polymer and the method may include manufacturing the pallet body at
the location from where the goods are to be transported, using
polymer supplied by a sender seeking to transport the polymer.
[0108] The method may include repeatedly using the pallet after
attaching the accessory to the feet of the pallet body and the
method may include renting out the pallet as part of a pool of
pallets, after attaching the accessory to the main body.
[0109] The method may include removably attaching one or more deck
extension accessory to one or more edges of the load deck of the
pallet body. In one embodiment, the load deck has a size of about
40.times.48 inches and the load surface of the pallet is increased
to 52.times.44 inches with the addition of the deck extension
accessory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0110] For a better understanding of the present invention, and to
show how the same may be carried into effect, the invention will
now be described by way of non-limiting example, with reference to
the accompanying drawings in which:
[0111] FIG. 1A is a three-dimensional view of a pallet in
accordance with the present invention, from above;
[0112] FIG. 1B is a three-dimensional view of the pallet of FIG.
1A, from below;
[0113] FIG. 1C is a top plan view of the pallet of FIG. 1A;
[0114] FIG. 1D is a side view of the pallet of FIG. 1A:
[0115] FIG. 2 is a three-dimensional view of a main body of the
pallet of FIG. 1A;
[0116] FIG. 3 is a detail view of a corner of the main body of FIG.
2;
[0117] FIG. 4 is a three-dimensional view of a plurality of the
bodies of FIG. 2, stacked in a nesting arrangement;
[0118] FIG. 5 is a three-dimensional view of an accessory of the
pallet of FIG. 1A;
[0119] FIG. 6 is a detail view of a corner of the accessory of FIG.
5;
[0120] FIG. 7 is a three-dimensional view of a plurality of the
accessories of FIG. 5, stacked in a nesting arrangement;
[0121] FIGS. 8A and 8B are sectional views through part of the
pallet of FIG. 1A, taken at VIII-VIII, showing the engagement and
attachment between the main body of FIG. 2 and the accessory of
FIG. 5. In FIG. 8A, the parts are shown shortly before the
engagement and in FIG. 8B they are shown in engagement;
[0122] FIGS. 9A and 9B are sectional views through part of the
pallet of FIG. 1A, taken at IX-IX, showing the engagement and
attachment between the main body of FIG. 2 and the accessory of
FIG. 5. In FIG. 9A, the parts are shown shortly before the
engagement and in FIG. 9B they are shown in engagement;
[0123] FIG. 10 is a sectional view through part of a deck of the
pallet of FIG. 1A, showing two inserts received in recesses of the
deck;
[0124] FIG. 11 is a sectional view of a first embodiment of an
identification tag being fitted in a foot of the pallet of FIG.
1A;
[0125] FIGS. 12A and 12B are an exploded side view and a sectional
side view of a second embodiment of an identification tag being
fitted in a foot of the main body of the pallet of FIG. 1A;
[0126] FIG. 13 is a plan view of an alternative embodiment of a
corner of the accessory of the pallet of FIG. 1A;
[0127] FIGS. 14A and 14B are sectional side views at XIV-XIV of the
accessory of FIG. 13, showing an exploded view and an assembly,
respectively, of an identification tag being fitted in the corner
of the accessory;
[0128] FIG. 15 is a three-dimensional view of a deck extension
accessory for use with the pallet of FIG. 1A;
[0129] FIGS. 16A and 16B are detail sectional views of parts of the
main body of the pallet of FIG. 1A, fitted with the deck extension
accessory of FIG. 15;
[0130] FIG. 17 is a three-dimensional view of an edge insert for
use with the pallet of FIG. 1A;
[0131] FIG. 18 is a detail sectional view of part of the main body
of the pallet of FIG. 1A, fitted with the edge insert of FIG.
17:
[0132] FIG. 19 is a three-dimensional view of a corner sleeve of
the pallet of FIG. 1A;
[0133] FIGS. 20A and 20B are detail sectional views through part of
the load deck of the pallet of FIG. 1A, shown in FIG. 20A inside a
two-part mould and shown in FIG. 20B after de-moulding;
[0134] FIG. 21 is a three-dimensional view of a pillar insert;
[0135] FIG. 22 is a top view of the pillar insert of FIG. 21;
[0136] FIG. 23 is an oblique side view of the pillar insert of FIG.
21;
[0137] FIG. 24 is a top three-dimensional view of a corner of a
pallet, with pillar inserts inside its pillars;
[0138] FIG. 25 is a side view of a corner of a pallet with pillar
inserts and a main body of FIG. 2 supported on top of the pillar
inserts;
[0139] FIG. 26 is a three-dimensional view of a castor insert for
the main body of FIG. 2;
[0140] FIG. 27 is a three-dimensional view of a castor insert for
the accessory of FIG. 5;
[0141] FIG. 28 is a three-dimensional view of walls of a first
embodiment of a pallet bin in accordance with the present
invention, in a partly folded condition;
[0142] FIG. 29 is a three-dimensional view of the walls of FIG. 28,
in a fully folded condition;
[0143] FIG. 30 is a three-dimensional view of the walls of FIG. 29,
placed along an edge of a pallet body of the pallet bin in
accordance with the present invention, the walls being spaced above
the pallet body;
[0144] FIG. 31 is a three-dimensional view of the walls and pallet
body of FIG. 30, with the walls in a partly opened condition;
[0145] FIG. 32 is a three-dimensional view of the walls and pallet
body of FIG. 30, with the walls in a fully opened condition;
[0146] FIG. 33 is a detail three-dimensional view of a corner of a
pallet bin in accordance with the present invention, comprising the
walls and pallet body of FIG. 32;
[0147] FIG. 34 is a front view of the pallet bin of FIG. 32;
[0148] FIG. 35 is a side view of the pallet bin of FIG. 32;
[0149] FIG. 36 is a three-dimensional view of two of the pallet
bins of FIG. 32, stacked on top of each other.
[0150] FIG. 37 is a three-dimensional view of walls and lid of a
second embodiment of a pallet bin in accordance with the present
invention, in a partly folded condition;
[0151] FIG. 38 is a three-dimensional view of a pallet bin,
including the main pallet body of FIG. 2 and the walls of FIG. 37,
in a fully folded condition;
[0152] FIG. 39 is a three-dimensional view of the pallet bin of
FIG. 38, with the walls in a fully opened condition and with the
lid closed; and
[0153] FIG. 40 is a three-dimensional view of four of the pallet
bins of FIG. 39, stacked on top of one another.
DETAILED DESCRIPTION OF THE DRAWINGS
[0154] Referring to the drawings, a pallet in accordance with the
present invention is generally indicated by reference numeral 10,
whereas a main body of the pallet is generally indicated by
reference numeral 12 and a bottom accessory of the pallet is
generally indicated by reference numeral 14. For the sake of
simplicity, the main body 12 is also referred to as the "top" and
the accessory 14 as the "bottom".
[0155] Referring to FIGS. 2 to 4, the main body (top) 12 can be
made of any suitably light, strong and durable material, but is
preferably a unitary moulding of reinforced polymeric material and
it includes a load deck 16 and nine feet 18 protruding from the
underside of the load deck. The top of the load deck 16 defines a
generally planar load surface 20 and the underside of the deck
defines an under-surface 22 that is continuous between the feet 18.
The feet 18 are disposed at the corners, mid-way along the edges
and in the centre of the load deck 16. In other embodiments, the
top 12 may include feet 18 disposed only in its four corner regions
or optionally also a central foot.
[0156] The deck 16 is made up of a continuous lattice of webs and
flanges that define an array of cube-like cavities 24, each
defining a rectangular recess or aperture 26 that is surrounded by
a rectangular flange or frame. The alternate cavities 24 have
apertures 26 that are disposed in the load surface 20 and in the
under-surface 22 of the load deck 16. The under-surface 22 is
bevelled towards the load surface, around the periphery of the load
deck 16. The load deck 16 has a depth that is more than 20 mm and
that is preferably about 36 mm.
[0157] Each foot 18 is hollow and has tapering outer walls 28 that
give it a generally octagonal profile. Each foot defines a foot
recess 30 in its centre, surrounded by tapered inner walls 32.
Further, each foot 18 has four recesses 34 extending upwards from
its bottom 36, so that the foot has four angled pillars 38, each
defined between the inner walls 32, outer walls 28 and two recesses
34. At the bottom of each pillar 38, there is a first attachment
formation in the form of a rectangular aperture 40.
[0158] The hollow construction of each foot 18, together with the
angled structure of its inner and outer walls 32,28 allows the feet
of one body (top) 12 to be received in a nesting manner inside the
hollow insides of the feet of another body 12 below it, when the
bodies are stacked on top of one another, as shown in FIG. 4. In
the nested condition, the underside 22 of the load deck 16 of the
body 12 above rests against the load surface 20 of the body below
it, and this abutment of the load decks prevents the feet 18 of the
upper body from entering the insides of the feet of the lower body
too far and thus prevents the feet from getting stuck in the
nesting arrangement as result of a taper lock.
[0159] As can be seen in FIGS. 8A and 8B, the body (top) 12
includes a cross member 41 that is generally aligned with the load
deck and spans the foot recess 30, between the inner walls 32 of
the foot 18. The cross member 41 serves to carry tensile loads on
the inside of the foot 18, to resist deformation of the foot in
racking or stacking with a heavy load on the pallet. In some
preferred embodiments, the cross member 41 has a deeper profile
than the load deck 16, but with the top of the cross member aligned
with the load surface 20, this means that the bottom of the cross
member extends lower than the under surface 22 and as a result,
when the bodies 12 are nested, the bottom of the cross member of
the upper body 12 rests on the top of the cross member of the lower
body 12 and this abutment of the cross members 41 prevent the
pillars 18 of the bodies 12 from entering too deeply into each
other.
[0160] Referring to FIGS. 5 to 7, the accessory (bottom) 14 can
also be made of any suitably light, strong and durable material,
but is preferably a unitary moulding of reinforced polymeric
material. It is generally rectangular and has nine "second"
attachment formations 42, disposed at its corners, midway along its
sides and at its centre. The size of the bottom accessory 14
corresponds to that of the load deck 16 and the positions of the
attachment formations 42 correspond with those of the feet 18.
[0161] The bottom accessory 14 includes outer beams 44 that extend
between attachment formations 42 disposed at the corners and midway
along the sides of the accessory, to form a rectangular structure
(referred to in the art as a "picture frame"), as well as inner
beams 46 that extend from the central attachment formation to each
of the attachment formations midway along the sides, to form a
cross structure (referred to in the art as a "cruciform"). The
construction of each of the beams 44,46 is very similar to that of
the load deck 16, with a continuous lattice of webs and flanges
defining cavities 24, with apertures 26 on the top and bottom of
each beam and with a bevelled edge. However, the depth of the beams
44,46 is substantially less than that of the load deck 16, making
the load deck better suited to bear bending loads, but the beams
suited to bear tensile loads.
[0162] Each of the attachment formations 42 defines a generally
octagonal accessory recess 48 and an upstanding hollow accessory
protuberance 50 in the centre of the recess. The walls of the
protuberance 50 are angled and define steps 52, so that each corner
region of the recess 48 can receive the lower end of a pillar 38 of
its corresponding foot 18 in a snug manner between the walls of the
recess 48 and protuberance 50 and the steps 52.
[0163] At each corner of each recess 48, a second attachment
formation is provided in the form of a pair of resilient clips 54
with barbs facing outwards. In the illustrated embodiment, the
upper ends of the clips 54 protrude above the upper surfaces of the
adjacent outer beams 44, but in some preferred embodiments, the
depths of the beams and the lengths of the clips are selected so
that the clips do not protrude above the upper surfaces of the
beams 44,46 at all.
[0164] Like in the case of the top body 12, the bottom accessory 14
can be stacked to form a nested stack of accessories as shown in
FIG. 7. The hollow construction of the protuberance 50 and its
tapering walls allows the protuberance of a lower one of the
accessories to be received inside the protuberance of an accessory
immediately above it, in a nesting arrangement. Like in the case of
the top body 12, the bottom accessory 14 is shaped and configured
such that the undersides of its beams 44,46 rest on top of the
upper surfaces of the beams of the accessory below it, when nested,
without the protuberance 50 of the lower accessory extending too
far into the protuberance of the top accessory. In some
embodiments, part of the upper bottom accessory 14 may extend into
the recess 48 of the lower bottom accessory, when nested, but the
extent to which this can happen is limited by the abutment of the
beams 44,46 to prevent any part of the upper accessory from
damaging the clips 54.
[0165] Referring to the lattice structure of the load deck 16 and
beams 44,46: The load deck 16 has an even thickness throughout and
has a uniform support capacity and the load surface 20 and under
surface 22 are uniformly the same strength right through the deck,
which allows for better handling of uneven loads on top of the
deck. Further, the load deck 16 is easily washable it includes no
closed cavities 24, but has openings in its load surface 20 and
under surface 22 (apart from the feet 18). This feature also allows
air or water to flow easily through the whole pallet 10, which
allows much better cooling and temperature control with reduced
energy requirements when transporting the pallets in trucks or
transport containers (e.g. in a "cold chain"). The improved control
of air flow throughout the pallet 10 and fruit and other perishable
products packed on the load deck 16, allows the pallets and their
loads to be cooled more effectively and efficiently. There is thus
also less wasted product because quicker ripening and other high
temperature problems can be avoided. Further, better cooling and/or
temperature control during transport of fresh produce on the pallet
10 allows longer shelf lives of the produce, when sold in retail.
The effective cooling characteristics of the pallet 10 allows for
direct containerisation, eliminating the requirements for
pre-cooling in cold storage before shipment. Fruit can now be
shipped immediately and reach the destined markets earlier and
ensure a longer shelf life.
[0166] The construction of the pallet 10 from polymeric (plastic)
material also has the advantage of inhibiting or preventing mould
or bacteria formation on the pallet, as is often found with wooden
pallets, because of wood impurities. The plastic material can also
be made resistant to bacteria, mould, etc., which again contributes
to longer shelf life of produce transported on the pallet 10.
Moisture in wood contributes to condensation in closed containers
and causes and promotes product damage, fungus, mould and mildew
growth as well as metal oxidation. The use of polymeric material
also eliminates the presence of any additional moisture source in
the container normally associated with un-dried or insufficiently
dried timber.
[0167] The uniform structure of the deck 16 also prevents fork lift
blades from entering the deck from below (through human error) at
any ribs, planks not properly joined to the pallet, etc.--as in the
case of prior art pallets.
[0168] The top body 12 and bottom accessory 14 are formed in
separate moulds where the molten polymer enters the mould cavities
through the middle foot 18 or middle attachment formation 42, as
the case may be, through a large gate. The purpose of the large
gate is to keep the fibres in the polymer long to achieve good
mechanical properties for the weight of the polymer matrix. The
polymer matrix can include glass fibre and other additives such as
UV resistors colorants, additives for compatabilizing different
polymers, fire retardants that assist in compliance with the UL
2335 specifications, reinforcing particles, fillers, etc. Even
anti-bacterial additives can be provided should it be required.
There are many other additives that could be used in the
formulation should there be a requirement. By injecting the polymer
through a single injection point, the formation of weld lines can
be controlled and there is the freedom to cool the mould in such a
way that, even if weld lines are formed, they are strong because
the temperature of the polymer on opposing sides of the welds are
within 5% of one each other. The mould can also be designed so that
the polymer flows into the mould in such a way that the welds meet
mainly in the feet of the pallet.
[0169] As an alternative to moulding from a single, large gate, the
body 12 or accessory 14 can be moulded through multiple gates, e.g.
a central gate and four spaced apart gates, all built into the
mould and shutting off the mould cavity at the bounding wall of the
mould, with mouldable material fed to each gate from a hot runner
system.
[0170] The material properties of long glass fibre with polyolefins
in a matrix give lower creep and thermal expansion values that are
even better than aluminium and magnesium and are very close to
thermal expansion values of steel, but the glass fibre must be
longer than 10 mm if used in polypropylene and more than 20% by
weight of glass fibre is required. The glass fibres are inert to
fire and costly fire retardant additives only need to be provided
for the polymer portion of the material. The material as described
herein is thermally stable in temperatures ranging between -20
degrees C. and 40 degrees C.
[0171] Referring to FIGS. 8 and 9, when the body 12 and bottom
accessory 14 are to be attached together, each foot 18 is attached
to its corresponding attachment formation 42 and at the same time:
[0172] the lower ends of the foot's pillars 38 are received inside
the recess 48 of the attachment formation 42; [0173] each foot's
protuberance 50 is received inside the recess 30 of the attachment
formation (in the illustrated embodiment, the protuberance 50
extends about one third into the depth/height of the recess 30);
[0174] the outer walls 28 of the feet 18 abut outer walls of the
recess 48; [0175] outer walls of the protuberance 50 abut the inner
walls 32 of the foot; and [0176] each pair of the clips 54 engage
the aperture 40 of its corresponding pillar 38 in a clipping
manner.
[0177] The engagement between the foot 18 and its attachment
formation 42 can bear downwards compressive loads because the
bottoms 36 of the pillars 38 simply press against the bottom of the
recess 48. The engagement can also bear shear loading, i.e.
side-to-side forces acting on either the body 12 or the bottom
accessory 14, by the walls of the pillars 38 pressing against the
walls from the recess 48 and the walls of the protuberance 50
pressing against the walls of the recess 30. Accordingly, the only
forces that the engagement of the clips 54 in the apertures 40,
need to bear, are vertical forces that seek to pull the body and
the accessory apart. These forces are borne in the clips 54 as
tensile forces and the clips are thus not exposed to significant
shear or bending forces during normal use and are only exposed to
mild bending forces during engagement or disengagement of the body
12 and the bottom accessory 14.
[0178] The hollow inside of each pillar 38 forms a release aperture
56 in which an appropriately shaped device can be inserted from
above, to press against bevelled edges 58 of the clips 54, to press
the clips closer together and thus release the engagement of the
clips with the aperture 40. The bottom accessory 14 can thus be
removed from the body 12, if required, and can be re-fitted to the
same or another body. This allows inter-changeability of the bodies
12 and accessories 14 to allow easy maintenance of the pallet 10 by
replacing a damaged body 12 or bottom accessory 14.
[0179] The outside dimensions of the load deck 16 and of the bottom
accessory 14 are about the same and this differs from other pallets
with nestable upper parts. Further, the beams 44,46 of the bottom
accessory 14 cover more than 55% and typically 65% of the area of
the underside of the pallet 10.
[0180] Referring to FIGS. 1 to 9, in use, the main body 12 can
serve the purpose of a pallet that need not be stacked or racked
and that need not bear heavy duty, although in practical
experimentation, it has been found that the strength of the top
body 12 is sufficient to bear the loads required during stacking
and/or racking. In particular, a typical example of the top body 12
can bear static loads of about 1375 kg (while transporting on a
lifting fork) and can bear static loads exceeding 4,000 kg. The
body 12 also only deflects to a maximum of 17 mm when supported on
opposing edges (e.g. in a racking system), under a load of 1.375
kg. The low deflection of the body 12 allows it to be used in racks
without the accessory 14, thus allowing space underneath the load
deck 16 for movement of automated warehousing equipment.
[0181] Further, the body 12 on its own is quite light in weight and
can be nested. The weight of the main body 12 is less than 40
pounds, preferably less than 30 pounds and typically about 8 kg
(17.6 pounds) and is significantly less than any existing nesting
pallet that can do the same duty as that of a one-way wooden
pallet. The body 12 can thus be used on its own to receive a load
on its load deck and can be used to transport that load, with the
advantages of the light weight of the body. Further, the body 12
can be transported in a cost-effective manner to the location where
it is to be loaded, by nesting the bodies together during
transportation and thus saving space.
[0182] In some cases, the benefits of using the body 12 to
transport loads are even greater, if they can be produced at the
location from where products are to be transported. In particular,
in the chemical industry, where very large quantities of polymer
material products need to be transported on pallets from the
polymer suppliers to their customers, polymers from the suppliers
can be used to manufacture the bodies 12 at the site from where the
polymer material products are to be transported. Similarly, in the
cases of manufacturers of suitable reinforcing fibres (e.g. glass
fibres), glass fibres from the manufacturers can be used to
manufacture the bodies 12.
[0183] The cost of manufacturing the bodies 12 at the site from
where products are to be despatched or manufacturing the bodies
elsewhere and transporting them to the site, is much lower than the
cost of current practices of transporting conventional wooden
pallets to the site, in complete form.
[0184] Further, there are savings in transport costs because the
low weight of the body 12 allows more product to be transported in
a load, without increasing the overall weight of the load. E.g. one
extra 25 kg bag of polymer product can be carried on every top body
12 (weighing about 8 kg), which is capable of serving the same
function as a conventional wooden pallet weighing about 42 kg. By
adding the extra bags of polymer to each pallet load, up to 800 kg
of additional product can be transported in each payload, without
additional payload costs. When the bodies are transported without
load (whether to depots, distributors, retailers, washing depots,
or the like), at least half the transport cost is saved because
more than twice the number of bodies 12 can be transported (in the
nested configuration described above) for the same volume and
weight of conventional wooden pallets (assembled with nails). These
transport savings reduce the energy required for transport, which
results in substantial benefits in reducing carbon emissions. In
addition, the pallet 10 holds the environmental advantages that it
does not lead to deforestation as in the case of wooden pallets and
the materials of which the pallet 10 are made are recyclable. The
sustainability and environmental benefits are very substantial and
allow the pallets 10 to compete on an economic basis with
conventional wooden pallets.
[0185] Once the bodies 12 are available at the site from where
goods are to be transported, they are loaded by placing the goods
on the load surfaces 20 and the goods and pallets are transported
to their destinations, where the goods are off-loaded. Under normal
trading conditions, a pallet used to transport the goods up to this
point would either have been a one-way wooden pallet that would be
discarded, or it would have been a durable, heavy duty pallet that
can be re-used, but that would have had the disadvantages of costly
transport up to this stage (because of the weight and
non-nestability of the pallets). However, the bodies 12 of the
present invention can be collected after use and can be transported
cost-effectively because of their low weight and nesting ability
and can be re-used.
[0186] To the inventor's knowledge: No existing wooden pallet used
in transporting products has the ability for its feet to nest.
There are however plastic pallets that can nest but no existing
nesting pallet can carry more than a 2800 lbs (1270 kg) dynamic
weight load. No existing plastic pallet that can compete with the
pallet 10 on performance (i.e. in terms of static and dynamic
loading capacity, racking with bending, etc.) has the ability for
its feet to nest. No existing nesting pallet can simultaneously
meet the requirements of "one man lift less than 35 lbs" (i.e. the
"OSHA requirement"), a racking weight in a 40.times.48 inch pallet
with a height of 5.75 inches, of more than 2800 lbs with safety of
50% and bending less than 20 mm. However, the pallet 10 separated
into the main body 12 and bottom accessory 14 has nesting
capability insofar as the main bodies are nestable and the bottom
accessories are nestable. Pallet 10 meets all these
requirements.
[0187] The combination of nestability with the load bearing and
racking requirements is a major breakthrough in the worldwide
pallet industry. This was achieved through the material formulation
and the design of the pallet 10. When the feet 18 are attached to
their corresponding receiving formations 42, the complete pallet 10
becomes a structural member with very low weight i.e. less than 44
lbs.
[0188] The fact that the pallet 10 is made in two parts (the body
12 and bottom accessory 14) and is thus not moulded in a single
shot mould (as in cases where the top deck and the bottom deck of a
pallet are moulded together in a single shot), there is no need to
slide cores from the sides of the mould and the moulds are much
less complex. A single-shot pallet where the complete pallet is
made with the top and bottom deck together in a unitary moulding
can never nest to save transport costs. Such a single-shot pallet
also necessarily has more weight because it needs to be shaped to
allow for the moulds to come away from the ribs in a taper design,
but the design of the pallet 10 does not require a taper in the rib
structure.
[0189] The spaces between the feet 18 serve as access for the forks
of lifting apparatus such as fork-lift trucks, to lift the bodies
12 (or pallets 10), with or without a load.
[0190] When the bodies 12 are to be re-used, they can be used as
described above, or they can be used in the form of a heavy duty
pallet 10 which is capable of stacking, racking and heavy loads, by
attaching the bottom accessory 14 to the body 12 as described
above. The bottom accessory 14 strengthens the pallet 10 for
stacking because the beams 44,46 can distribute the weight of the
pallet 10 (and its load) on the load of a pallet below it. The
bottom accessory 14 allows the pallet 10 to be racked because the
beams 44,46 can bear tensile loads, thus increasing the stiffness
of the pallet substantially, against bending or deflecting under
its load. The bottom accessory 14 also enhances the strength of the
pallet 10 generally by providing a pallet that is stiffer than the
body 12 on its own.
[0191] In this formation the complete pallet 10 will preferably
weigh less than 35 lbs or 16 kg and still satisfy the OSHA
requirements in the USA for a one man lift, have a dynamic load
capacity exceeding 1.5 metric tonne, have a static load capacity of
up to 12 metric tonnes or more and be able to rack more than 1300
kg with deflection of less than 20 mm. The inventor believes that
these properties can be achieved at room temperatures of about 23
degrees C., but also in temperatures as low as -20 degrees C. and
in temperatures as high as 40 degrees C., or more.
[0192] The pallet 10 can thus be used for many purposes once the
bottom accessory 14 has been attached to the body 12, but depending
on the intended use of the pallet, it may be preferable to release
the attachment of the accessory to the body, e.g. to transport the
bodies and bottom accessories separately in nested (more space
efficient) stacks, it may be preferable to use the bodies 12 on
their own again, or the like.
[0193] The invention holds the advantage that the provision of the
bottom accessory 14 that can be releasably attached to the body 12,
allows the body to be converted from a light duty ("one-way" or
"export") pallet to a heavy duty ("return" or "pool") pallet, as
required, while the invention also holds the advantages of economy
of space and weight when the body 12 and bottom accessory 14 are
separate. The design of the pallet 10 further gives it the strength
required for most heavy duty applications, with a significantly
lower cost and weight of the pallet.
[0194] As can best be seen in FIG. 1D, the recesses 34 between the
pillars 38 of the feet 18 form apertures, when the feet 18 are
attached to the attachment formations 42. The design of the feet 18
with these apertures formed by the recesses 34, saves weight and
adds structural strength to the pallet 10.
[0195] Referring to FIG. 10, each of the many recesses or apertures
26 can receive an insert 60 (referred to as a "grommet" in the art)
of a slip resistant material. The plurality of apertures 26 allows
the number and positions of grommets 60 to be selected to suit the
needs for particular uses of the pallet 10. The number and
positions of the grommets 60 can thus be selected for the load
surface 20 (to prevent loads from slipping on the pallet), in the
undersides of the beams 44,46 (to prevent the pallets from slipping
around) as well as in the underside 22 of the load deck 16 and/or
the top of the beams 44,46 (to prevent unwanted slippage of the
pallet relative to the forks of a lifting device).
[0196] Referring to FIGS. 11 to 14, the pallet 10 can be fitted
with identification tags, such as RFID tags, to assist in pallet
identification.
[0197] In the embodiment shown in FIG. 11, a first embodiment of an
RFID tag 62 is inside a protective cylindrical housing 64 that is
fitted to the body 12 by inserting it from below into the foot
recess 30 and receiving an upper end of the housing in a
complementary formation 66 formed on the cross member 41. The lower
end of the housing 64 is received in a complementary aperture in
the top of the accessory protuberance 50 and the housing and tag 62
are kept captive inside the foot 18, where they are protected by
the surrounding structure of the foot. The tag 62 can be removed
easily, when the body 12 and bottom accessory 14 are separated as
described above.
[0198] In the embodiment shown in FIGS. 12A and 12 B, a second
embodiment of an RFID tag is a strip that is adhesively attached to
a carrier 74 that can be inserted into the recess 30 and fitted
onto the complementary formation 66, to be held in place by
flexible clips 76 that engage apertures defined in the inner walls
32 of the pillars 38. The RFID tags are thus fitted securely, deep
inside the recesses 30, where they are protected against damage.
Further, these tags allow the main body 12 to be identified, with
or without the bottom accessory 14.
[0199] In the embodiment shown in FIGS. 13, 14A and 14B, a third
embodiment of an RFID is a strip that is sealed between two strips
of plastic material, to form a strip-shaped RFID device 78.
Elongate slots 80 are defined inside the bottom accessory 14 in
which the devices 78 can be received. Each slot 80 has retaining
barbs 82 on opposing sides of the slot, so that the device 78 can
be flexed to fit between the barbs and be inserted into the slot
80, after which the device straightens once inside the slot, so
that it is held captive by the barbs. The device 78 allows the
bottom accessory 14 to be identified, with or without a main body
of the pallet. The position of the device 78, close to the
underside of the bottom accessory 14 reduces the risk of impact
from the forks of a lift truck, because the forks are practically
always angled (to prevent pallets and/or loads slipping forward
when driving), so that the forks ends are above the ground and thus
higher than the device 78.
[0200] The separate RFID tags that can be fitted on the main body
12 (shown in FIGS. 12A and 12B), bottom accessory 14 (shown in
FIGS. 13 and 14) and/or the assembled pallet 10 including a main
body and accessory (shown in FIG. 11), allows the pallet 10 and/or
its component parts 12,14 to be tracked together or separately.
[0201] Referring to FIGS. 15 and 16, a deck extension accessory 84
is provided that includes hook formations 70 and clips 72, similar
to those of the edge insert 68 shown in FIGS. 17 and 18, that can
grip the edge of the load deck 16. In addition, the accessory 84
has longer clips 86 that can grip the edge of the load deck 16 in
areas where it is deeper, e.g. in the regions of the feet 18 (with
the hook formations received in the insides of the pillars 38, in
addition to the recesses 26).
[0202] The accessory 84 is configured to extend along two
perpendicular edges of the load deck 16 and has an upper surface
that is generally aligned with the load surface 20 of the load
deck, when the accessory has been fitted. Accordingly, when the
accessory is fitted, it engages the edge of the load deck 16 (with
the hooks 70 and clips 72,86) and extends the size of the load
surface 20. The ends 88 of the accessory 84 are bevelled, so that
when two accessories are fitted to the body 12, they increase the
size of the load surface 20 at all four edges of the load deck
16.
[0203] The effect of fitting the accessories 84 is to increase the
load surface of the pallet body 12 and the accessories 84 can be
removed again, which means that with the use of the accessories, it
is possible to alter the size of the load surface, to suit loading
needs.
[0204] As mentioned above, in some industries, certain pallet sizes
are preferred to optimise available space, e.g. in the chemical
industry, a 1.3 m.times.1.1 m pallet is preferred for one-way
shipment of products (or 52.times.44 inch in the USA), because it
allows shipping containers and vehicles to be loaded more
optimally. However, in other industries, e.g. the transport of
fast-moving consumer goods, other sizes (e.g. a 1.2 m.times.1.0 m
pallet, or 48.times.40 inches in the USA) may be the standard that
fits in warehousing systems (which could require racking and/or
stacking and which may be automated) etc. These pallet dimensions
are merely by way of example and there are many other standard
sizes for pallets, but the principles remain the same--that
different sizes of pallets are required to meet the different needs
of pallet transportation and if a pallet is made in any size, it
will either not be possible to use it in other applications or its
use in other applications will compromise on its performance (in
terms of space utilisation, pallet weight, load capacity, or the
like). However, with the use of the accessory 84, the pallet 10 of
the present invention can be used as a larger pallet, when the
accessories 84 are fitted and can later be used as a smaller
pallet, when the accessories 84 are removed--and vice versa. This
supplements the ability to change the other properties of the
pallet 10 by including or excluding the bottom accessory 14, as
described above.
[0205] As an example of the versatility the accessories 14,84
provide, the pallet of the present invention can be used as a
large, light weight, one-way pallet to distribute products from
manufacturers (as is presently done on wooden pallets that are
discarded). Once the products have been delivered, the pallets 10
can be converted to smaller sizes by removing the accessories 84
and/or can be given more strength by adding the accessories 14, as
and when required.
[0206] The pallet 10's dimensions could be changed to achieve all
the standardised pallet configurations of "CP1" to "CP9" for the
chemical industry as well as the USA chemical standards of
40.times.48 inch.times.5.75 inch high, 52.times.42 inch and
45.times.45 inch as well as the printing pallet sizes of
44.times.44 inch, 48.times.42 inch, and 42.times.42 inch. To the
inventor's knowledge, none of the presently available pallets that
satisfy these requirements are nestable.
[0207] It is also possible to make the accessory 84 of an impact
absorbing material, such as rubber, to protect the load deck
16.
[0208] Referring to FIGS. 17 and 18, edge inserts 68 can be fitted
to the load deck 16 by inserting a hook formation 70 into an
aperture 26 of the load deck 16, at an edge of the deck and
gripping the deck with a clip 72. When the edge insert 68 is
received in this manner, it provides an upstanding ridge 73 that
protrudes above the load surface 20 to assist in preventing loads
from sliding on the load surface 20 or sliding off the load deck
16.
[0209] Referring to FIG. 19, a corner sleeve 90 is shown that can
be used with the pallet 10. The sleeve is made of a suitable
durable material, preferably a material that can absorb shocks and
protect the pallet, e.g. rubber or a thermoplastic elastomer. The
sleeve 90 has an internal cavity 92 that is shaped and dimensioned
to fit snugly around a pillar 38 of the main body 12 of the pallet
and the cavity is open at its top and bottom ends. Two hook
formations 70 are provided at the top of the sleeve 90 in a
perpendicular arrangement relative to each other. The hook
formations 70 are shaped similarly or identically to those of the
deck extension accessory 84 and the edge insert 68 described above
and can be received in a recess 26 of the load deck 16. At its
lower end, the sleeve 90 has two protuberances 94 that are
receivable in the recesses 48 of the bottom accessories 14.
[0210] The corner sleeve 90 is fitted to a corner of the main body
12 by sliding it over a pillar 38 and clipping the hook formations
70 into recesses on opposing sides of the load deck's corner. The
engagement of the sleeve 90 around the pillar 38 and of the hook
formations 70 in the apertures 26 hold the sleeve 90 firmly in
place on the main body 12, irrespective of whether or not the main
body 12 is fitted with a bottom accessory 14. When a bottom
accessory 14 is fitted on the main body 12, the lower end of the
pillar 38 (which protrudes below the sleeve 90) is received in the
recess 48 of the bottom accessory 14 in the normal way, with the
protuberances 94 on either side of it.
[0211] The sleeve 90 has upper walls 96 that extend around the
corner of the load deck 16, has lower walls 98 that extend around
the corner of the bottom accessory 14 and has spaced ribs 100
between these walls 96,98. The walls 96,98 and ribs 100 protect the
corners of the pallet 10 against impact.
[0212] Referring to FIGS. 20A and 20B, when manufacturing the main
body 12, an upper mould part 102 and a lower mould part 104 are
pressed together and mouldable material, preferably molten
polymeric material reinforced with long glass fibres, is injected
into the mould cavity of the two-part mould to form the main body.
Once the moulded material has solidified, the mould parts 102 and
104 are moved apart (i.e. the mould is opened) and the main body 12
is de-moulded (i.e. removed from the mould).
[0213] As can be seen in FIG. 20B, the load deck 16 comprises of an
array of cube structures, each extending around one of the cavities
24. Each cube structure comprises four webs 106 on four sides of
the cavity 24 and a flange at the top or bottom of the cavity. The
cube structure thus extends on five of the six orthogonal sides of
the cavity 24--leaving one side (to or bottom) open. The deck 16 is
configured such that cavities 26 that are open to the load surface
20 and cavities that are open to the under surface 22 alternate and
the result is that the webs 106 and flanges 108 have a castellated
cross-sectional profile as shown in FIG. 20B. Apertures 26 are
formed in the centre of each of the flanges 108 shown in FIG. 20B
so that each flange forms a frame around its aperture and this
aperture reduces the weight of the main body 12 and provides for
the attachment of grommets (shown in FIG. 10 with reference numeral
60). The part of the flange 108 that extends around each aperture
26 adds to the rigidity of the load deck 16 and assists in forming
a contiguous load surface 20 or under surface 22, as the case may
be.
[0214] As can be seen in FIG. 20A, the castellated profile of the
load deck 16 is formed in the single injection moulding step
described above by intermittent protuberances 110 that extend
downwardly from the upper mould part 102, that are received between
upwardly extending protuberances 112 of the lower mould part 104.
In order for the moulded load deck 16 to be de-moulded easily, each
of the webs 106 has a slightly angled orientation, i.e. it extends
at an obtuse (non vertical) angle relative to the load surface 20
and/or under surface 22.
[0215] The main purpose of the webs 106 is to provide strength to
the load deck 16 and more particularly, to ad stiffness to the load
deck and prevent deflection under loads. In this regard, each web
106 acts as a longitudinal beam extending under the load surface 20
an in order to provide stiffness, the web's cross sectional profile
should preferably have a large second moment of area, in relation
to its neutral axis 114. As can be seen in FIG. 20A, the sides of
the protuberances 110 and 112 are in contact in the vicinities of
the centres of each of the webs 106, so that apertures 116 are
formed in each of the webs, in the vicinity of the neutral axis
114. The result is that each web 106 has material at its top and
bottom, i.e. in the regions of its upper and lower edges, that is
integrally connected to the flanges 108 and this material in each
web 106 has a large second moment of area, because it is relatively
far from the neutral axis 114. Each web 106 can thus provide great
stiffness as a result of its high second moment of area, but is
light in weight because of material saved by forming the apertures
116. These webs 106 with their apertures 116 extend in two
perpendicular, axial directions underneath the load deck 16 and the
result is that the load deck is exceptionally strong for its
weight.
[0216] In embodiments of the invention where the main body 12 can
be nested and the accessory 14 can be nested, when the main body
and accessory are not attached together, the pallet 10 (comprising
the main body 12 and attached accessory 14) can carry a load of
more than 2800 lbs for longer than 30 days with a 50% factor of
safety in a warehouse rack where the pallet is only supported on
two opposing feet and it does not bend more than 20 mm after 30
days.
[0217] The main body 12 (without the accessory 14 attached) can
carry a dynamic load of up to 2800 lbs when a forklift is carrying
the accessory and its load for loading into containers, trucks or
the like, without the load deck 16 bending to the extent that goods
carried on the load deck fall off.
[0218] The main body 12 can be used to export goods in shipping
containers instead of a much heavier wooden pallet (of about 65
lbs) on what is commonly referred to as "export pallets", "one way
pallets", or "white" pallets. Conventional export pallets use about
33% less wood than what an equivalent size pallet that satisfies
the requirements for pool pallets (where a pool pallet means a
re-usable returnable pallet that can be rented on an issue fee
(trip fee) basis to a client instead of the client buying new
pallets).
[0219] The two piece pallet 10 of the present invention, together
with the removable deck extension accessories 84, provides the
flexibility to compete with the conventional "white" one-way export
pallet on price for the first export shipment (i.e. where the price
of the main body 12 is compared to the price of a "white" pallet)
and then instead of land-filling, discarding or using the "white"
pallets' wood for repairs of other wooden pallets, using the main
body 12 as an integral part of a new fast moving consumer goods
(FMCG) pool pallet that is stackable, rackable and durable, once
the deck extensions accessories 84 are removed from the pallet.
This way the cost of manufacturing the main body 12 again is
avoided. In the wooden pallet case there is a lot of waste as the
wooden "white" pallet is the wrong size and is not durable enough
and thus cannot be used as an FMCG pallet and is manufactured for
only one way use--as one of its names suggest. The present
invention could assist greatly in reducing
deforestation--especially if the pallet 10 becomes a standard. This
advantage is further amplified by commercial benefit, since
disposal fees are becoming payable in countries receiving goods on
a pallet, in an attempt to discourage land-filling and improper use
of the world's natural resources
[0220] The main body 12 can be manufactured for the export market
where the main body is the size required in the destination country
e.g. 40 by 48 inches with a height of less than 5.72 inches for the
USA, and deck extension accessories 84 can be attached around the
pallet's load deck to extend the load deck horizontally to increase
the size of the load deck for the optimal use for export in
containers. This enlargement can be to any suitable size, e.g. to a
size of 52.times.44 inches. The deck extension accessory 84 can be
removed, leaving a rackable, durable pallet with size 40.times.48
inches, the accessory 14 can be attached to the main body 12 to
make the pallet 10 a durable pool pallet for use in the FMCG
trade.
[0221] The main body 12 with the deck extension accessories 84 that
enlarge the load deck, is also nestable.
[0222] The pallet 10 can be dismantled easily by unclipping the
accessory 14 from the feet 18, when it needs to be transported
empty and the main bodies 12 and accessories 14 can be transported
in separate nested arrangements. In typical scenarios, the same
number of pallets 10 can be transported in five trucks as
conventional "white" pallets can be transported in twelve trucks at
present, because of the reduced volume occupied by the nested parts
of the pallet 10. This allows substantial payload cost savings in
containers and on trucks, aeroplanes and trains and will have a
major impact on the environment and carbon footprint reduction of
the world.
[0223] The pallet 10 weighs less than 44 lbs in any embodiment
where it has a load deck size commonly used, but with a load deck
size of 40.times.48 inches, it weighs less than 35 lbs and it is
expected to be the lowest weight pallet satisfying the requirement
of the FMCG market for racking, stacking and/or durability.
[0224] When goods are carried on the pallet 10, the client can add
an extra 60 lbs payload on the pallet as this is the difference
between the weights of conventional wooden pallets and the pallet
10, allowing about 1500 lbs on a 53 foot truck and about 1000 lbs
extra weight in a 40 foot container to be carried free of charge,
by utilizing the pallet weight differential between the wooden
pallet and this pallet.
[0225] Penalties that result from pallets becoming overweight, e.g.
with weight gained by water drenching in rain, inconsistent water
levels in pallets, etc. are avoided with the pallet 10 and the load
can be optimally controlled without traffic and other penalties
being incurred.
[0226] For every 52 trucks-loads using the pallet 10, there is a
saving of one complete truck load--from a CO2 carbon footprint
perspective or put differently, 1400 lbs of additional product can
be carried on every 53 foot truck load--at no additional cost.
[0227] The corner sleeve 90 that can be moulded from a
thermoplastic elastomer (TPE) or rubbery compound, can be used to
avoid impact on the corners of the pallet 10 to increase the
serviceable life of the pallet, before it needs to be recycled.
Breakages from dropping the pallets 10 on their corners will also
be reduced by the corner sleeve 90. The corner sleeve 90 cannot be
removed from the pallet 10 while the pallet is assembled with the
main body 12 and accessory 14 attached together. The present
invention allows for the use of strapping tape to secure and
strengthen the feet 18 of the main body 12 when it is used without
the accessory 14.
[0228] In another embodiment of the present invention, the middle
foot 18 of the main body 12 can be made with the same configuration
as the second attachment formations 42 of the accessory 14 and the
corresponding middle attachment formation of the accessory 14 can
be made with the same configuration as a foot 18 of the main
body--i.e. the middle foot 18 and middle second attachment
formation 42 as shown in the drawings, can be inverted.
[0229] Referring to FIGS. 22 to 23, pillar inserts 160 are shown,
which are shaped to fit inside the hollow pillars 38 of the pallet
10. Each pillar insert 160 is a unitary moulding that forms a
peripheral wall 162 to complement the inside of a pillar and three
vertical webs 164 extending between the walls 162. The vertical
height of the webs 164 is less than that of the walls 162.
Apertures 166 are defined on the lower, outer corners of the insert
160 and a resilient clip 168 extends into the recess, with an
outwardly facing barb.
[0230] FIG. 24 shows a corner of the pallet 10 with four pillar
inserts 160 fitted inside the pillars 38 that make up a corner foot
18. The upper edges of the walls 162 are lower than the load
surface 20 and the upper edges of the webs 164 are lower still. The
clips 168 are clipped into apertures defined at the lower corners
of the pillars 38, although this is not visible in FIG. 24.
[0231] Referring to FIG. 25, a corner of a pallet 10 is shown with
pillar inserts 160 in the pillars of its corner foot 18 and a top
body 12 is supported above the pallet 10, with the lower ends of
the pillars of the top body 12 supported on the pillar inserts 160.
In this arrangement, the load surface 20 of the top body 12 is
elevated well above the floor (or other surface) supporting the
pallet 10 and this is required for reasons of hygiene when handling
certain foodstuffs, e.g. in the candy industry. In a typical
embodiment, the load surface 20 will be about 230 mm above the
floor, thus meeting the industry requirement of being at least 200
mm above the floor.
[0232] In the arrangement shown in FIG. 25, the top body 12 can
serve the purpose of carrying goods continually, e.g. the goods can
be received, handled and/or despatched on the body 12, while the
pallet 10 only serves to support the top body 12 when necessary,
e.g. when the goods needs to be stored in a rack. There is a gap of
about 55 mm between the load deck 16 of the top body 12 and the
pallet 10, thus leaving sufficient space for easy entry by the
forks of a lifting device, to lift the top body 12 off the pallet
10. The pillars of the top body 12 also withdraw quite easily from
the pallet 10, when lifted, because of the shallower nesting depth.
Further, the pillars 38 of the pallet 10 are structurally
strengthened by the pillar inserts 160 and it is these pillars that
are most exposed to damage, because they are closest to the ground
and are exposed to damage by lifting forks.
[0233] When pallets are transported from one location to another
location, e.g. when goods are despatched from manufacturers or
suppliers, the goods are loaded on a pallet body 12, which is light
and inexpensive, but can bear the static and dynamic loads of the
goods during handling and transportation. The weight saving
resulting from the use of a light pallet during transportation,
rather than a heavy duty pallet allows for an increase in
transportation efficiency, whether viewed as a reduction in
transported load, allowing more payload mass without increasing the
combined load of the payload and pallets, reducing energy
requirements for transport, of the like.
[0234] When the pallet body 12 is received in a location where it
is required to have additional structural properties that allows it
to be stacked, racked, or the like, e.g. where the pallet body 12
needs to be used in a warehousing system or in a pallet pool, an
accessory 14 is attached to the feet 18 of the pallet body 12, to
form a pallet 10, which has all the properties required for a
warehouse or pool pallet. The pallet 10 can thus be used in its
assembled state at the location where the body 12 was received and
when the body 12 needs to despatched, e.g. when the goods are
despatched from a distribution warehouse, the accessory 14 can be
removed from the pallet body 12, so that the goods are despatched
and transported only on a pallet body 12, without the accessory 14
and thus again with the weight saving and benefits mentioned
above.
[0235] If preferred, instead of attaching an accessory 14 to a
pallet body 12 at the location where a pallet is required that has
the improved structural properties imparted by the accessory 14,
the accessory 14 can be provided already attached to a pallet body
12, to form an assembled "slave" pallet 10 and the pallet body 12
that needs to be supported, can be received on top of the slave
pallet 10, with its feet 18 being nested inside the feet 18 of the
slave pallet 10. This approach requires an additional pallet body
12 to be available for each accessory 14, but it holds the
advantage that the accessories 14 need not be attached or removed
from pallet bodies 12.
[0236] The slave pallet 10 may preferably have pillar inserts 160
inside the pillars 38 of its feet 18, so that the feet 18 of the
top body 12 only partly nest inside the feet of the slave pallet,
thus allowing space between the load decks of the slave pallet 10
and top body 12 for lifting forks to enter, making de-nesting
easier and improving the strength of the slave pallet's feet.
[0237] The term "location" need not refer only to a single
building, yard, or the like, but could be an area of operation,
such as a regional pallet pool. It is thus not essential that the
body 12 is never transported with an accessory 14, but that it is
transported without an accessory 14 for at least some of the
time--especially for transport over long distances.
[0238] Apart from the substantial savings in transport costs
mentioned above, the method of supporting top bodies 12 only at
times and/or locations where needed, holds the advantage that only
a small number of accessories 14 are required, in relation to the
number of pallet bodies 12 that are used to transport goods. The
method effectively requires the accessories 14 only to be available
at the locations where pallets are required with improved
structural properties for racking, stacking and the like. There are
at any time a vast number of pallets in transit between locations
where these improved structural properties are required and
effectively, the invention avoids the need for accessories 14 for
each of the pallets in transit, and allows the number of
accessories 14 to be reduced to satisfy the needs only at locations
where they are really required.
[0239] In other embodiments of the invention, a pallet 10 (whether
in the form of a pallet body 12 only, an accessory only 14 or a
combination of a pallet body and its attached accessory) is wheeled
in the sense that it has wheels on its underside that allows it to
be moved easily over a floor by rolling action of the wheels. Such
a wheeled pallet can receive a pallet body 12 (e.g. a pallet body
loaded with goods) and support the pallet body 12 while also
allowing the pallet body 12 to be moved around by rolling action of
the wheeled pallet, without the need to lift the pallet body, e.g.
with fork lift trucks or jacks.
[0240] The movement of the pallet body 12 on top of a wheeled
pallet can typically be done by hand and fork lift trucks (or the
like) are only required for lifting the pallets, e.g. for loading
or offloading onto or from trucks, ships, trains, etc. The
reduction of the need to lift and manoeuvre the pallet bodies with
fork lift trucks or the like, drastically reduces their exposure to
damage. (Bearing in mind that such lifting devices are the most
prominent causes of damage to pallets.)
[0241] Further, the ability of the pallets 10 to be moved on wheels
by hand drastically reduces the floor space required to store goods
on the pallets, because it is not necessary to leave sufficient
space between pallets for each pallet to be accessible by fork lift
truck or jack. The resulting improvement in floor space utilisation
can in many cases obviate the need for racking or stacking of
pallets 10.
[0242] Referring to FIGS. 26 and 27, the wheels or castors 170 are
attached to adaptors 172 that are shaped to clip onto the
undersides of feet of a pallet body 12, or the wheels/castors 170
are attached to adaptors 174 that are shaped to be received inside
the protuberances 50 of an accessory 14, with a snap fit. Instead,
the wheels can be fixedly attached to the undersides of the pallet
body 12 or accessory 14. The adaptor 174 shown in FIG. 27 shows a
castor 170 that has been attached to the adaptor by four bolts 173,
but a central hole 175 has is defined in the adaptor, so that it
can be used with a castor that requires a central bolt for
attachment--such as the castor 170 shown in FIG. 26.
[0243] In the event that finished goods need to be racked before
shipping to a distribution centre, end customer, warehouse (e.g.
cold storage), or the like, a pallet 10 will be required that
includes a pallet body 12, attached to an accessory 14, without
wheels. However, once the pallet 10 no longer needs to be racked,
the accessory 14 can be unclipped from the pallet body 12 and the
pallet body and its load of goods can be despatched, while the
accessory 14 remains behind at the location where racking is
required.
[0244] In the event that finished goods are required on pallets
with wheels, an accessory 14 with wheels can be used to receive a
loaded pallet body 12, but the accessory 14 can be configured so
that it does not attach (clip) to the pallet body 12. Accordingly,
when the pallet body 12 and its load are lifted to load them onto a
truck, train, or the like, to despatch them, the pallet body is
lifted free from the wheeled accessory, which remains behind and
only the pallet body and its load are despatched.
[0245] By only Transporting goods loaded on pallet bodies 12,
transportation the additional weight of the accessories 14 is
avoided in the whole logistics value chain. This allows for
shipment of up to four times the number of pallet bodies 12 on the
same truck (2448 of them), compared to using the same truck to
transport wooden pallets (612) including top and bottom decks or
just wooden top decks with feet that cannot nest.
[0246] Referring to FIGS. 29 to 36, apparatus for the handling of
goods, in the form of a first embodiment of a pallet bin 118 in
accordance with the present invention, includes a pallet 10
(whether comprising only a pallet body 12 or a pallet body 12 with
an accessory 14 on its underside) and walls 120,122 that are
pivotally attached together.
[0247] Each wall 120,122 has a bottom edge 124, a top edge 126,
lateral edges 128, an outer surface 134 and an inner surface 136
and the walls are pivotally attached together with attachment means
in a side-by-side arrangement, with a pivot axis that coincides
with the lateral edges. The exact configuration of the pivotal
attachment means may vary, e.g. it may include a part that forms a
pivot axle (not shown) and formations (not shows) on the lateral
edge 128 that extends at least partly around the axle and that can
swivel around the axle, or any other suitable pivotal attachment.
Preferably, the pivotal attachment of the walls 120,122 at their
lateral edges 128 is a permanent attachment, without any components
that are removable.
[0248] The pallet bin 118 includes six walls; two rigid walls 120
and two pairs of inwardly pivotable walls 122, each of these pairs
extending between the lateral edges of the rigid walls. The rigid
walls 120 are configured to extend along opposing edges of the load
deck 16 when the pallet bin 118 is assembled and each pair of
inwardly pivotable walls 122 is configured to extend along one of
the two remaining edges of the load deck. In the illustrated
example, the rigid walls 120 are much wider than each of the walls
122 of each inwardly pivotable pair, but the dimensions of the
walls may vary, for different embodiments of the invention.
[0249] The walls 122 in each pair of inwardly pivotable walls are
attached together at their adjacent lateral edges 128 by pivotal
attachment means, to form an inwardly pivotable corner, where the
walls can pivot inwardly to a folded position in which their outer
surfaces 134 face each other, and outwardly to an erected or open
position in which the walls are aligned.
[0250] Each lateral edge 128 of each rigid wall 120 is attached to
a lateral edge 128 of a wall 122 from a pair of inwardly pivotable
walls, to form an outside corner 132, where the walls 120,122 are
configured to pivot between a folded position in which their inner
surfaces 136 face each other, and an erected or open position in
which the walls are positioned with a 90 degree angle between their
inner surfaces.
[0251] Each wall 120,122 is a unitary moulding that comprises an
array of webs 138 defining cavities 140 between them, much like the
construction of the load deck 16. Each cavity 140 is open on both
sides of the wall and has a tapered shape, extending between a
large opening 142 on one side of the wall and small opening 144 on
the opposite side of the wall, with a flange 146 extending around
the small opening. The tapered shapes of the cavities 140 allow for
withdrawal of moulds when making the walls 120,122 and adjacent
cavities are shaped to taper towards opposite sides of the walls.
The resulting structure with alternate cavities 140 in a two
dimensional array along the wall 120,122 tapering to opposing sides
of the wall, and with their flanges 146 on opposing sides of the
wall, form a remarkably strong, yet very light structure. The
structural strength of this construction is especially remarkable
when the wall 120,122 is compressed along the plane of the wall,
with the webs 138 and flanges 146 bearing the compressive loads in
a balanced manner (without a tendency to bend inwardly or
outwardly) and with the webs and flanges providing stiffness to one
another.
[0252] The cavities 24 along the edges of the load deck 16 and the
load deck's edges themselves, form deck attachment formations to
which the walls 120,122 can be removably attached. Along the bottom
edge 124 of each wall 120,122, a number of protuberances 148 are
formed, which are shaped complementally to the cavities 24 of the
load deck 16 and can be received inside the cavities. (In other
embodiments, the protuberances 148 could also have clips or the
like, to keep them in position inside the cavities.) Further, a
number of clip formations 150 are provided along the bottom edge
124 of each wall 120,122, which can grip the edge of the load deck
16 in a firm, but releasable, clipping manner.
[0253] Along the top edges 126 of the walls 120,122, positioning
formations in the form of tabs 152 and ridges 154 are provided,
that are shaped complementally to the undersides of the feet 18 of
the pallet body 12 and/or that are shaped complementally to the
undersides of the accessory 14.
[0254] When not in use, the bin 118 can be stored while occupying
very little space. The space saving features of the nestable body
12 and accessory 14 have been described above and in the earlier
patent applications. Further, the pivotal arrangement at the
corners 130,132 allow the walls 120,122 to pivot to a flat, folded
condition as shown in FIGS. 7 and 8, with the corners 130 pivoted
completely inwardly and the outer surfaces of the inwardly
pivotable walls 122 touching, and with the inner surfaces of the
walls 120,122 at each outside corner 132 touching.
[0255] To erect the pallet bin 118, the walls 120,122 are unfolded
from their folded position as described above with reference to
FIGS. 7 and 8, to a partly folded condition as shown in FIGS. 6 and
9 and to an open condition as shown in FIGS. 10 to 14, with the
inwardly pivotable walls 122 in each pair in alignment and with the
walls 120,122 at each outer corner 132 at a right angle. When the
walls 120,122 are in their open condition, they are positioned to
extend along the periphery of the load deck 16 and are removably
attached to the load deck by inserting the protuberances 148 into
the cavities 24 along the edges of the load deck and by allowing
the clip formations 150 to grip the edges of the load deck.
[0256] When the walls 120,122 are attached to the load deck 16, the
pallet bin 118 is in an assembled or erected condition and a
storage cavity 156 is defined on the inside of the walls, above the
load deck. The pallet bin 118 can be used in the conventional
manner for receiving, storing, transporting, etc. of goods inside
the cavity 140. When the pallet bin is not needed for any period,
it can be disassembled by unclipping the clip formations 150 from
the edges of the load deck 16 and withdrawing the protuberances 148
from the cavities 24. The walls 120,122 can be folded and the body
12 can be nested in other bodies, etc.
[0257] The pallet bins 118 can be stacked by placing one pallet bin
on top of another, so that the weight of the upper bin is carried
by the walls 120,122 of the lower bin. This is made possible by the
strength of the walls 120,122 in compression, as described above.
Further, the upper pallet bin 118 is held in position relative to
the lower bin by engagement of the tabs 152 and ridges 154 with the
underside of the pallet 10 (i.e. the body 12 or accessory 14, as
the case may be) above it.
[0258] If required, the walls 120,122 of the present invention can
be shaped and dimensioned to be used with a load deck that has been
extended by a deck extension accessory 84, by engaging the cavities
and edges of the deck extension accessory instead of the cavities
and edges of the load deck itself, as described above.
[0259] In another embodiment of the present invention (not
illustrated), the inwardly pivotable walls 122 may be omitted or
may be removable or may be made very low, so that the pallet bin
118 effectively only includes the body 12 and the rigid walls 120
on opposing sides of the load deck 16. This embodiment allows
elongate objects to be carried on the pallet body 12, while
protruding over the edges of the load deck, but while held in
position on the load deck by the rigid walls.
[0260] In another embodiment of the present invention (not
illustrated), an accessory in the form of an extension is provided,
that can be received on the load deck 16 and/or on the underside of
the pallet 10, and that is configured to receive a standard sized
large object, especially a drum such as a 44 gallon drum. The
accessory need not be very high, e.g. it can be about 50 to 75 mm
high, but must be high enough to prevent lateral movement of the
objects. An accessory can be attached to the load deck to prevent
the objects from sliding off the load deck, but in a preferred
embodiment, another accessory is placed on the underside of a
pallet 10 that is stacked above the pallet carrying the objects and
in this configuration, the objects form a stable support for the
pallet above it.
[0261] Referring to FIGS. 37 to 40, a second embodiment of a pallet
bin is shown. Features that are common between the pallet bin of
FIGS. 28 to 36 and the pallet bit of FIGS. 37 to 40, are identified
by the same reference numerals, with a suffix "2" in FIGS. 37 to
40.
[0262] The pallet bin 118.2 is very similar to the bin 118 of FIGS.
28 to 36, but its walls 120.2 and 122.2 are significantly
higher--about the same height as the cross-sectional dimensions of
the pallet body 12. As a result, the bin 118.2 is generally
cube-shaped. As a result, when the walls 120.2,122.2 of the pallet
bin 118.2 is folded, as shown in FIG. 38, it can be laid flat to
span generally across the load deck 16 of the pallet body 12.
[0263] The pallet bin 118.2 also includes a lid 176 that is
pivotally attached to the upper edge of one of the rigid walls
120.2 and is shown in an open position in FIG. 37 and in a closed
position in FIG. 39. In FIG. 38, the lid 176 lies horizontally, on
an inverted (upside-down) position on top of the folded walls
120.2, 122.2.
[0264] The lid 176 can be locked closed, attached to the upper edge
of the rigid wall 120.2, opposite from its pivotal attachment.
However, the lid 176 includes a hatch 178 that is pivotally
attached to a frame 180 that extends around the periphery of the
lid 176. The frame 180 includes recesses 48 and protuberances 50
disposed at its four corners and midway along each edge, at
positions corresponding to the attachment formations 50 and
recesses 48 of the accessory 14. As a result, the bottoms of feet
18 of a pallet body 12 can be received inside the recesses, around
the protuberances 50. This nesting of feet 18 on the lid 176 allows
pallet bins 118.2 to be stacked safely on top of each other, as
shown in FIG. 40, without risk that a pallet bin will slide off the
pallet bin supporting it and while the walls 120.2, 122.2 of the
pallet below, bears the weight of the pallet bin(s) above it.
[0265] The rigid walls 120.2, and thus the pivotable walls 122.2
and lid 176 are attachable to the load deck 16 of pallet body 12 by
releasable latches 182.
[0266] In another embodiment of the invention, the feet 18 are not
moulded with the rest of the main body 12, but are moulded
separately and are then attached to load deck 16. The attachment
between the feet 18 and the load deck 16 may be permanent or may be
releasable. This embodiment of the invention holds the advantages
that the feet 18 may be made of different material from the rest of
the main body 12, e.g. low cost material can be used for one-way
(export) pallets or material that is more resistant to the abrasion
and/or impact the feet are likely to endure through contact with
the forks of lifting apparatus, in pallet pools. The feet 18 are
more prone to damage by such forks and in embodiments where the
feet are removably attached to the load deck 16, damaged feet can
be replaced, thus maintaining the pallet 12 in a serviceable
condition at only the cost of one foot. Lastly, different pallet
heights are required for use in different applications and
different sizes of the feet 18 can be moulded, so that the pallet
10 can be assembled to have a selected height.
[0267] The strength and stiffness requirements of the load deck 16
can vary, depending on the intended purpose of the pallet 10 and in
order to ensure sufficient strength, when necessary and to reduce
weight and costs, when possible, the thickness (i.e. depth) of the
load deck can be selected to be thicker (e.g. 36 mm) for pallets 10
that are capable of racking. Likewise, the number of cavities 24
and webs 106 in the load deck 16 can be increased to provide a
stiff/strong load deck, or the numbers of cavities and webs can be
reduced to provide a lighter load deck.
[0268] Some of the webs 106 within the load deck 16 are slightly
thicker than the others and have no apertures 116, so that they
serve as beams that strengthen the load deck. These thicker webs
preferably extend all the way between opposing edges of the load
deck 16, to provide strength all the way up to the points of
attachment of the edge inserts 68, deck extension accessories, or
walls 120, to the load deck.
* * * * *