Pallet

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PCT/US02/30856

PALLET

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to pallets for supporting freight, goods, or other materials.

2. Background Art

Current plastic pallets have upper and lower decks that are optimally designed to serve their diverse purposes. Equally important to the specific structure of the upper and lower decks is the latching mechanism which secures the decks together in an assembled configuration. During handling, lateral movement of the upper and lower decks with respect to one another can cause the two decks to become disengaged. Therefore, a need exists for a pallet which provides a more secure latching feature as well as sufficient lateral constraint for the latching feature to enhance the attachment of the upper and lower decks so that they cannot be separated during use.

SUMMARY OF THE INVENTION

Therefore, it is an object according to the present invention to provide a pallet which includes more secure latching of the upper and lower decks in the assembled configuration.

It is another object according to the present invention to provide a pallet having improved lateral stability of the top and bottom decks with respect to each other.

It is another object according to the present invention to provide a pallet having guide features which improve alignment of the upper and lower decks for assembly.

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It is still another object according to the present invention to provide a plastic pallet which is lightweight, strong, and durable.

Accordingly, a pallet is provided which includes spaced upper and lower decks. A plurality of receiving areas are formed in one of the upper and lower decks, where each receiving area includes at least one latch member extending therefrom. A plurality of corresponding supports extend from the other of the upper and lower decks, where each support includes at least one latch receiver extending therefrom, the latch receiver having a plurality of spring arms. The latch receiver is adapted to receive the latch member such that engagement of the receiving areas and corresponding supports securely joins the upper and lower decks in an assembled configuration.

In accordance with a preferred embodiment of the present invention, the receiving areas are integrally formed within a bottom surface of the upper deck, and the supports are integrally formed with and project upwardly from a top surface of the lower deck. Each receiving area includes a plurality of ribs, and each latch member extends outwardly from one of the ribs at a lower end thereof. In addition, each latch member preferably tapers upwardly and outwardly from the lower end of the rib and terminates in a generally horizontal shoulder portion.

Correspondingly, each support includes a plurality of ribs, and the plurality of spring arms includes two arms attached to one of the ribs at an upper end thereof. The arms are connected by a receiving face or bridge portion such that the latch receiver has a generally U-shaped appearance, where the bridge portion is adapted to receive the shoulder portion of the latch member thereunder. The latch receivers are preferably flexible, such that engagement of the receiving areas and corresponding supports causes the latch member to contact the receiving face and deflect the latch receiver outwardly from its resting position, and passage of the shoulder portion past the bridge portion allows the latch receiver to return to its rest position and securely retain the latch member therewithin.

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In further accordance with a preferred embodiment of the present invention, guide members at least partially surrounding each latch receiver. Each guide member includes a wall structure having a first portion extending generally parallel to at least one latch receiver and a second portion extending along at least 5 one side of one latch receiver. Guide members located at the corners of the pallet each include a curved wall which at least partially surrounds two adjacent latch receivers. The guide members are preferably tapered with the lower end of each guide member being wider than the upper end thereof. Correspondingly, each receiving area includes compartments which are sized to receive the individual guide 10 members, where each compartment preferably includes one latch member.

Engagement of the guide members with the receiving area compartments provides lateral stability for the assembled upper and lower decks.

The pallet according to the present invention is generally rectangular and includes twelve supports and twelve corresponding receiving areas. The lower 15 deck includes a generally rectangular perimeter portion, an integrally formed longitudinal rail joined to the perimeter portion and extending along a longitudinal axis of the pallet, and two integrally formed transverse rails joined to the perimeter portion and the longitudinal rail and extending parallel to a transverse axis of the pallet. Together, the perimeter portion, the longitudinal rail, and the transverse 20 rails define six large openings in the lower deck. Corner supports project from the four corners of the perimeter portion, medial supports project from each end of the longitudinal rail, and transverse supports project from the ends and midpoint of each transverse rail. In a preferred embodiment, the corner supports, and medial supports each include eight spaced latch receivers, and the transverse supports each include 25 six spaced latch receivers.

In addition, a pallet according to the present invention is provided having an upper deck including a plurality of receiving areas formed therein, each receiving area including at least one latch member extending therefrom. The pallet further includes a lower deck including a plurality of supports extending upwardly 30 therefrom, each support including at least one latch receiver extending therefrom, where the latch receiver includes a plurality of spring supports. The latch receiver

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PCT/US02/30856 is adapted to receive the latch member such that engagement of the receiving areas and corresponding supports securely joins the upper and lower decks in an assembled configuration.

Still further, a latch assembly is provided according to the present invention for securely joining the upper and lower decks in an assembled configuration. The latch assembly includes at least one latch member disposed within each receiving area, the latch members each including a generally horizontal shoulder portion which tapers downwardly and inwardly toward a bottom surface of the receiving area. The latch assembly further includes at least one flexible latch receiver extending upwardly from each support, the latch receivers each having a plurality of spring arms connected to the support and a receiving face attached to the arms, wherein the receiving face is adapted to receive the shoulder portion of the latch member thereunder. In operation, engagement of the receiving areas and corresponding supports causes the latch member to contact the receiving face and deflect the latch receiver outwardly from its resting position, and passage of the shoulder portion past the receiving face allows the latch receiver to return to its rest position and securely retain the latch member therewithin, thereby securing the upper and lower decks in the assembled configuration.

The above objects and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGURE 1 is a top perspective view of an assembled pallet according to the present invention;

FIGURE 2 is a bottom perspective view of the pallet of FIG. 1 ;

FIGURE 3 is a top plan view of the pallet of FIG. 1;

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FIGURE 4 is a bottom plan view of the pallet of FIG. 1;

FIGURE 4a is an enlarged bottom plan view of a corner portion of the pallet shown in FIG. 4;

FIGURE 5 is a front elevational view of the pallet of FIG. 1, the rear elevational view being a mirror image thereof;

FIGURE 6 is a left side elevational view of the pallet of FIG. 1, the right side elevational view being a mirror image thereof;

FIGURE 7 is a top perspective, exploded view of the pallet of FIG. 1, showing the upper and lower decks aligned for assembly;

FIGURE 8 is a bottom perspective view of the upper deck of the pallet of FIG. 7;

FIGURE 8a is an enlarged perspective view of a comer portion of the upper deck of FIG. 8;

FIGURE 9 is a top perspective view of the lower deck of the pallet of FIG. 7;

FIGURE 9a is an enlarged perspective view of a comer portion of the lower deck of FIG. 9, wherein the lower deck corner portion is adapted to engage the corresponding upper deck corner portion shown in FIG. 8a;

FIGURE 10 is a cross-sectional view taken along line 10-10 of FIG. 1 showing the upper and lower decks prior to assembly; and

FIGURE 11 is a cross-sectional view taken along line 11-11 of FIG.

showing the upper and lower decks in an assembled configuration.

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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring first to FIGS. 1-6, a pallet according to the present invention is illustrated and designated generally by reference numeral 10. Pallet 10 includes two separately molded parts, namely an upper deck 12 and a lower deck 5 14. Upper deck 12 and lower deck 14 are injection molded of a suitable plastic material, such as high density polyethylene, polypropylene, or filled polypropylene. In plan view (FIGS. 3 and 4), pallet 10 is generally rectangular in shape with rounded corners and has symmetry about a longitudinal axis 16 and a transverse axis 18 thereof. The symmetrical two-piece injection molded plastic construction of 10 pallet 10 affords substantial strength and durability, simplicity, and easy assembly.

As explained below, upper and lower decks 12, 14 are adapted to be easily snapped together to form the assembled pallet illustrated in FIGS. 1-6.

Referring now to FIGS. 1,3, and 7-8, upper deck 12 has a solid top surface 20 interrupted by a series of apertures 22 which reduce the weight of upper 15 deck 12 and allow for drainage in the event that pallet 10 becomes wet. As shown in FIG. 8, a plurality of receiving areas 24, 26, 28 are integrally formed within the bottom surface 30 of upper deck 12. More specifically, at each of the four corners of the upper deck 12, a generally rectangular corner receiving area 24 is formed. At the mid-point of the left side 32 and right side 34 of the pallet 10, generally 20 square medial receiving areas 26 are formed. In addition, on either side of transverse axis 18, generally rectangular transverse receiving areas 28 are formed. Transverse receiving areas 28 are located along front side 36 of pallet 10, rear side 38 of pallet 10, and centrally intersecting with longitudinal axis 16. As shown in FIG. 8, receiving areas 24, 26, 28 all preferably have rounded corners. Of course, 25 other shapes and configurations of receiving areas 24, 26, 28 are fully contemplated in accordance with the present invention. These twelve receiving areas 24, 26, 28 are adapted to receive twelve corresponding supports 40, 42, 44 which are integrally molded with lower deck 14, as described below with reference to FIGS. 7 and 9-11.

As shown in FIG. 8, ribs 46 on the bottom surface 30 of upper deck 30 12 form an orthogonal pattern which runs parallel and perpendicular to the sides 32,

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34, 36, 38 while still other ribs 48 form another orthogonal pattern that is set at 45° to the first pattern. Ribs 46, 48 collectively form interconnected grid-like structures which span the spaces between receiving areas 24, 26, 28. As can be seen in FIG. 8, the bottom surface 30 of upper deck 12 is substantially planar in that receiving 5 areas 24, 26, 28 and ribs 46, 48 generally lie in a common plane.

In each of the receiving areas 24, 26, 28, there are a number of depending latch members or tabs 50, details of which are best shown in the enlarged view of FIG. 8a and the cross-sectional views of FIGS. 10 and 11. Each receiving area 24, 26, 28 includes a plurality of ribs 52, and each latch tab 50 is integrally and 10 rigidly formed with one of the ribs 52 and extends outwardly therefrom at a lower end 54 thereof. Each latch tab 50 preferably has a tapered portion 56 which tapers upwardly and outwardly from the rib lower end 54 and terminates in a generally horizontal shoulder portion 58 which is received by components of the mating support 40, 42, 44 of lower deck 14 as described below. By way of example, in the 15 embodiment shown each corner receiving area 24 and medial receiving area 26 includes eight latch tabs 50, with two latch tabs 50 disposed on each side thereof. Each transverse receiving area 28 includes six latch tabs 50, with two tabs 50 disposed on each of the sides disposed parallel to transverse axis 18 and one tab 50 disposed on each of the sides disposed parallel to longitudinal axis 16. Of course, 20 other numbers and placements of latch tabs 50 within receiving areas 24, 26, 28 may be utilized in practicing the present invention.

Referring next to FIGS. 7 and 9, lower deck 14 has a footprint which substantially matches that of upper deck 12, but differs substantially in structure. Lower deck 14 includes a generally rectangular perimeter portion 60, an integrally 25 formed longitudinal member or rail 62 joined to the perimeter portion 60 along the left side 32 and right side 34 of pallet 10 and extending along longitudinal axis 16. In addition, two integrally formed transverse members or rails 64 are joined to the perimeter portion 60 along the front side 36 and rear side 38 of pallet 10. Transverse rails 64 are also joined with the longitudinal rail 62 and extend parallel 30 to transverse axis 18 on either side thereof. Together, perimeter portion 60, longitudinal rail 62, and transverse rails 64 define six relatively large openings 66

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WO 03/028431 PCT/US02/30856 in lower deck 14. Perimeter portion 60 and rails 62, 64 preferably have beveled edges, and may optionally include apertures formed therein (not shown). The substantial amount of open area strategically placed within lower deck 14 minimizes the amount of material required without compromising structural rigidity.

As shown in FIGS. 7 and 9, twelve supports 40, 42, 44 corresponding respectively to receiving areas 24, 26, 28 are integrally formed with and project upwardly from a top surface 68 of lower deck 14. Corner supports 40 project from the four corners of perimeter portion 60, medial supports 42 project from each end of longitudinal rail 62, and transverse supports 64 project from the 10 ends and midpoint of each transverse rail 64. In the embodiment depicted herein, corner supports 40 and transverse supports 44 are generally rectangular in crosssection, while medial supports 42 are generally square in cross-section. Supports 40, 42, 44 preferably have smooth, rounded outside surfaces to prevent damage from the forks of a fork lift and, as with recesses 24, 26, 28, can have shapes other 15 than those illustrated herein. With reference to the assembled pallet views of FIGS.

1-2 and 5-6, the areas between supports 40, 42, 44 are fork-receiving regions which are intended to rest on the forks of a fork lift that can engage pallet 10 from any side 32, 34, 36, 38 thereof.

As best shown in the enlarged view of FIG. 9a and the cross-sectional views of FIGS. 10 and 11, each support 40, 42, 44 includes at least one latch receiver 70 extending therefrom. Latch receiver 70 is spring-loaded, having a plurality of spring supports or arms 74 which attach the latch receiver 70 to the support 40, 42, 44. In the embodiment shown herein, each support 40, 42, 44 includes a plurality of ribs 72, and each latch receiver 70 includes two spaced arms 25 74 attached to one of the ribs 72 at an upper end 76 thereof. Arms 74 are connected by a receiving face or bridge portion 78 disposed therebetween, such that latch receiver 70 has a generally U-shaped appearance. Of course, latch receiver 70 can include any number of spring arms 74 in accordance with the present invention.

As described below, latch receivers 70 are flexible, leaf springs that 30 are adapted to receive latch tabs 50 of upper deck 12 to form a latch assembly 79

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In further accordance with the present invention, guide members 80 are provided which at least partially surround each latch receiver 70 (FIGS. 9 and 9a). Each guide member 80 includes a wall structure having a first portion 82 extending generally parallel to latch receiver 70 and second portions 84 extending along the sides of latch receiver 70. Guide members 80 located at the corners of pallet 10 additionally include a curved wall 86 which at least partially surrounds two adjacent latch receivers 70 and includes a support rib 87 extending inwardly therefrom at the corner of pallet 10. Referring again to FIG. 8a, ribs 52 within each receiving area 24, 26, 28 form compartments 53 which are sized to receive the individual guide members 80, where each compartment 53 preferably houses one 20 latch member 50. Guide members 80 are inset from lower portion 88 of each support 40, 42, 44 for easier insertion into compartments 53 of corresponding receiving areas 24, 26, 28. In addition, guide members 80 are preferably tapered with the lower end 90 of each guide member 80 being wider than the upper end 92 thereof.

Advantageously, guide members 80 provide locating capability and alignment for engagement of supports 40, 42, 44 with corresponding receiving areas 24, 26, 28 during assembly of the upper and lower decks 12, 14 of pallet 10. Once the upper and lower decks 12, 14 are fully seated in an assembled position, the engagement of guide members 80 with receiving area compartments 53 provides lateral constraint preventing upper and lower decks 12, 14 from transverse movement with respect to one another which could cause the disengagement of the

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PCT/US02/30856 latch tabs 50 and latch receivers 70. The configuration of pallet 10 according to the present invention wherein many guide members 80 are provided to at least partially surround each individual latch receiver 70 greatly improves the lateral stability of the assembled pallet 10. Furthermore, guide members 80 protect the latch assembly 79 (FIG. 11) and limit the relative freedom of movement and reduce the forces that each latch assembly 79 will encounter.

FIGS. 7, 8a, and 10 depict how the two pallet decks 12, 14 are aligned for assembly. In FIGS. 8a and 10, corner support 40 and receiving area 24 are shown for exemplary purposes to illustrate the engagement of the upper and lower decks 12, 14, wherein their engagement is representative of the engagement between other receiving areas 24, 26, 28 and corresponding supports 40, 42, 44.

With reference now to FIGS. 4a, 8a, 9a, and the cross-sectional views of FIGS. 10-11, bridge portion 78 of latch receiver 70 is adapted to receive shoulder portion 58 of latch tab 50 thereunder. Engagement of receiving area 24 and corresponding support 40 causes tapered portion 56 of latch tab 50 to contact bridge portion 78 and deflect latch receiver 70 outwardly (to the left in FIG. 10) from its resting position. As decks 12, 14 are further advanced toward each other, passage of shoulder portion 58 past bridge portion 78 allows latch receiver 70 to spring inwardly to return to its rest position and securely capture latch tab 50 therewithin (FIGS. 4a and 11).

In operation, therefore, latch receiver 70 acts like a leaf spring. Due to the configuration of latch receiver 70 wherein two arms 74 are attached to each support rib 72, the force required to deflect latch receiver 70 is distributed over a large area, thereby decreasing the stress imparted to the plastic material.

Engagement of each of the twelve receiving areas 24, 26, 28 and corresponding supports 40, 42, 44 is accomplished simultaneously in the manner described above. Since each engaged receiving area 24, 26, 28 and support 40, 42, 44 includes multiple latch assemblies 79, a very secure connection between upper

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As shown in FIGS. 2 and 4, the bottom surface 94 of lower deck 14 has several series of reinforcing ribs 96 which provide structural rigidity for the 5 deck 14 and properly distribute the load carried by the upper deck 12 and the supports 40, 42, 44.

While a rectangular pallet 10 has been illustrated and described in the preferred embodiment, other shapes, e.g., square, are fully capable of embodying the features of the invention. The cross-sectional shapes of the receiving areas 24, 10 26, 28 and the supports 40, 42, 44 also may vary somewhat from those shown.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes 15 may be made without departing from the spirit and scope of the invention.