Pallet with strength plates and related methods

Loading platform with reinforcement panels and linked ways

Pallet with Strength Plates and Related Methods

Full description

Background of the invention

The present invention relates to the field of palletizing, more specifically to a pallet having improved resilience against impacts from material handling equipment, and to methods associated with making the same pallet.

Traditional pallets have a base layer and cargo layer separated by support blocks. Traditionally, the base and load layers have symmetrical end surface plates of common thickness, and are assembled on connecting plates that run the full length or width of the pallet. End deck boards are bolted through the connection boards to the support blocks to build the basic structure of the pallet. Intermediate surface panels are placed between the end surface panels. The end surface panels are also known as main panels.

To move the pallet and the load on it, forklift forks are inserted into the gaps between the base and load layers. If the forklift is not stopped in time, it may hit one of the end surface panels of the loading platform. The end surface plate may no longer be able to resist such shock over time. Such impacts weaken the pallet and significantly reduce its lifespan, causing the pallet to have to be repeatedly repaired and/or removed from service long before its expected life cycle.

In an effort to improve pallet durability, an intermediate deck plate can be positioned opposite the end deck plate to help withstand impacts from the material handling equipment. While this method is effective in generating more resistance, the result of failure is often the breakage of two plates rather than just one.

Another method is disclosed in Marchisano's US Patent No. 0220099. Patent 099 discloses a pallet containing at least two raceways, and a plurality of surface plates or support beams coupled to the raceways. In particular, the end deck boards in the loading bed are provided with a transverse groove or a low cut is made in the two runs in order to strengthen the loading platform. The end surface plates in the base layer are received in hollow parts of the runners to protrude in front of the runners. This can be effective in strengthening the platform, but cutting out the lower portion of the cargo layer end panels as well as the corresponding runners is a time-consuming process and, as a result, adds to the costs of constructing a loading layer.

Bas's Patent No. 7,056,074 disclosed the use of nail joint plates to strengthen wooden platform joints. Stud joint plates are placed between the upper surface of the support blocks and the plates in the bearing layer, between the lower surface of the support blocks and the bearing layer, and between the lower surface of the support blocks and the plates in the base layer. Each nail plate includes projections extending from the upper and lower surfaces, and a central hole to receive a conductive device. A corresponding connection means is used for each support block to connect the corresponding panels in the bearing and base layers to each support block. With the penetration of the corresponding nail joint plates into the resistant wooden surfaces. This can be effective in strengthening the pallet as well, but placing the dowel plates so that the center holes are aligned to receive the means of connection is dangerous and thus adds to the costs of constructing the pallet.

General description of the invention

In view of the foregoing, it is an object of the present invention to provide a pallet pallet with improved resilience to impacts from material handling equipment without increased cost compared to conventional wooden pallets.

This goal, in addition to other goals, characteristics, and features, according to the present invention, is achieved by providing a loading platform that includes a cargo layer and a base layer. The base layer can include a pair of spaced end deck boards, and a pair of connector boards perpendicular to the pair of end deck boards, such that each connector board and each end deck board have corresponding ends. To improve the flexibility of the pallet to impacts, a reinforcement plate can be coupled to each corresponding end of the connection plates in the base layer.

There may be a set of support blocks spaced between the base and load layers, thus creating a gap between them to receive a lifting member from a material handling equipment. A first set of fasteners can couple the bearing layer to the upper surface of the support block. A second set of fasteners can attach the base layer to the bottom surface of the support block assembly. The ends of the connector boards and corresponding stiffeners may be coupled to a first area of the bottom surface of the support blocks, and the ends of the end deck boards may be coupled to a second area of the bottom surface of the support blocks. The first and second zones of the bottom surface of the support blocks can lie at the same level.

One of the advantages of the reinforcement board is that it strengthens the ends of the connector boards in the base layer. Typically, the base layer end deck boards are the weak link in a pallet, and begin to separate when the base layer end deck boards receive a fairly large shock force. Without gussets, the impact force is transmitted from the end deck boards to the fasteners at the ends of the connection boards. However, in the presence of stiffeners, the impact force is transmitted from the end surface panels to the stiffeners adjacent to the fasteners at the ends of the connecting panels. Hence, the reinforcement plates reduce the separation of the terminals of the connection plates, which in turn helps in increasing the service life of the pallet.

Each reinforcement plate may include projections extending therefrom to penetrate a corresponding end of the connecting plates in the base layer. Each reinforcement plate includes a lower surface from which the protrusions extend, and an upper surface that can be free of protrusions. In addition, each reinforcement plate may have a width substantially equal to the width of a corresponding end to the connecting plates in the base layer.

The cargo layer may also include a pair of spaced end deck boards, and a pair of end deck boards perpendicular to the pair of end deck boards, such that each end deck and each end deck have corresponding ends. The top surface of each support block may be graduated to form a first area to receive a terminal surface plate end, and a second area to receive a breadboard end. An advantage of the stepped top surface of the support blocks is that when an impact force is applied to the end surface plate, it helps improve the resilience to impacts from the material handling equipment compared to a traditional wooden pallet. Alternatively, the upper surface of the support blocks may be located at the same level as the lower surface of the support blocks.

Another aspect of the invention is directed to a method of manufacturing a loading platform comprising two load layers and a base, such that the base layer includes a pair of spaced end deck boards, and a pair of spaced connection boards perpendicular to the pair of spaced end deck boards, such that Each breadboard and each terminal board have corresponding terminals.

The method may also include coupling a reinforcement plate to each corresponding end to the connecting plates in the base layer, and providing support blocks spaced between the base and load layers. The support blocks form a gap between the bearing layers and the base in order to receive a lifting member. Fasteners may be used first to attach the cargo layer to the upper surface of the support blocks. Secondary fasteners may be used to attach the base layer to the bottom surface of the support blocks. The ends of connector boards and corresponding stiffeners may be coupled to a first region of the bottom surface of support blocks, and the ends of end deck boards may be coupled to a second region of the bottom surface of support blocks.

Brief explanation of the drawings

Figure (1) is an overhead perspective drawing of a pallet loading platform according to the present invention.

Figure No. (2) is a lower perspective drawing of the loading platform shown in Figure No. (1).

Figure No. (3) is an enlarged perspective drawing of a corner of the loading platform shown in Figure No. 1.

Figure 4 is a side view of the support block shown in Figure 1 with its associated end deck boards, connection boards, and intermediate deck boards.

Figure 5 is a side view of another embodiment of the support block according to the present invention.

Figure No. (6) is a side view of another embodiment of the support block according to the present invention.

Figure 7 is a top view of the support block according to the present invention.

Figure No. (8) is a top view of an intermediate support block according to the present invention.

Figure No. (9) is a disassembled perspective drawing of a loading platform with a reinforcement plate according to the present invention.

Figure No. (10) is a disassembled side view of the pallet shown in Figure No. (9) with the stiffening plate.

Figure No. (11) is an overhead view of a pallet, showing the size and placement of the end deck boards and intermediate deck boards in the cargo layer according to the present invention.

Figure 12 is a top view of the pallet shown in Figure 11 showing support for casing corners for a range of common casing sizes.

Detailed description:

The present invention will now be described in more detail with the aid of accompanying drawings illustrating preferred embodiments according to the invention. However, this invention can be embodied in many different forms, and this should not be construed as a limitation of the embodiments mentioned herein. However, these models are presented so that the disclosure is comprehensive and complete and that the scope of the invention is fully conveyed to those skilled in the field. Reference numbers correspond to model elements, and numbers distinguished by one or two signs are used to indicate similar elements in alternative models.

Referring initially to Figures 1 to 4, the loading platform 10 according to the invention comprises a base layer 20, a cargo layer 30 and a plurality of stepped support blocks 40. The support blocks 40 are coupled between the base and load layers cargo layers 20 and 30, with a distance of 50 between them to accommodate at least one lifting member of material handling equipment such as a forklift.

It is preferable that the pallet 10 be made of wood. However, other types of materials or compounds may be used to form the pallet, at the discretion of those skilled in the art. These other materials or compounds may or may not include wood. For demonstration purposes, pallet 10 is made of wood.

As will be explained in more detail below, the top surface of the support blocks has multiple levels so that panels from cargo layer 30 are coupled at different levels to the support blocks. This form of support block is known as a single-step support block. Likewise, the bottom surface of the support blocks can have multiple levels so that panels from base layer 20 are coupled at different levels to the support blocks. This form of support blocks is known as double tiered support blocks. Features: Single and double tiered support blocks improve the flexibility of the pallet 10 to withstand impacts from material handling equipment.

The cargo layer 30 includes a pair of connector boards spaced 32 and a pair of end deck boards 34 spaced perpendicular to the connection boards so that the cargo layer assumes a rectangular shape. Each support block 40 includes a stepped upper surface that includes a first level 48a to receive end deck boards 34, and a second level 48b to receive connector board 32. In addition to the pair of connecting plates 32, additional support blocks 40 are positioned along the end surface plates 34 so that at least one additional connecting plate 32 extends parallel to the pair of connecting plates.

The stepped upper surface of each support block 40 is configured such that the first level 48a is above the second level 48 with a transition wall 49 defined between them. As a result, the end of each connecting plate 32 is adjacent to the transition wall 49 in the support block 40 associated with it. For manufacturing and assembly purposes, there is a tolerance between the transition wall 49 and the end of a corresponding connector board 32. However, the end deck boards 34 are usually positioned so that they protrude off the ends of the connector boards 32.

When an impact force is applied to an end surface plate 34, the force is transmitted to the ends of the connection plates 32 until the impact energy is dissipated along the length of the pallet. More specifically, the end-grained surface of the connection boards 32 absorbs the impact force rather than the bolt connections used to attach the end deck boards 34 to the support blocks 40. Hence, the stepped top surface improves resilience to shocks generated by the material handling equipment compared to With traditional wooden pallet.

The cargo layer 30 also includes spaced intermediate deck boards 36 that are coupled to the connection boards 32. The intermediate deck boards 36 are substantially parallel to the end deck boards 34. The exposed outer top surface of the deck boards is The intermediary 36 is at the same level as the exposed outer upper surfaces of the end surface panels 34.

Another advantage of the stepped top surface of support blocks 40 is that the thickness of the end surface panels 34 is independent of the thickness of the intermediate surface panels 36. An advantage is that this allows the use of thinner intermediate surface panels 36. The end result is a less expensive and more durable pallet 10 From a traditional wooden pallet.

In an alternative embodiment, the stepped upper surface of each support block 40' can be configured so that the first level 48a is below the second level 48b, with a transition wall 49' defined between them as shown in Figure 5. But this time One side of each end deck boards 34' is adjacent to the transition wall 49' in the associated support blocks 40'.

With reference to Figures 1 to 4, the base layer 20 also includes a pair of spaced end deck boards 24, and a pair of spaced connector boards 22 perpendicular to the end deck boards so that the base layer takes a rectangular shape. Each support block 40 also includes a stepped lower surface including a first level 42a to receive end deck boards 24 from the base layer, and a second level 42b to receive a connector board 22 from the base layer.

Therefore the upper and lower stepped surfaces of each support block 40 define a double stepped support block. An advantage is that the double stepped support block improves the flexibility of the pallet 10 to resist shocks from the material handling equipment.

There is an exposed outer bottom surface of each connection board 22 and an exposed outer bottom surface of each end deck boards 24 of the base layer 20 that are located in the same plane. As shown well in Figure 4, the stepped bottom surface of each support block 40 is configured such that the first level 42a is above the second level 42b with a transition wall 43 defined in between. As a result, one side of each end deck boards 24 of the base layer 20 is adjacent to the transition wall 43 in its associated support blocks 40.

In an alternative embodiment, the stepped bottom surface of each support block 40' may be configured so that the lower level 42a' is below the second level 42b' with a transition wall 43' located between them, as shown in Figure 5. But this time the end of each Connect plate 22' adjacent to the transition wall 43' in the support block 40' associated with it.

In yet another embodiment, the bottom surface of each 40'' support block may be in the same plane as shown in Figure 6. The end deck boards 24'' and the connection boards 22'' in the base layer are 20'' 'That it has the same thickness. In addition, the 22'' connection plate can protrude off the 24'' end surface plate in the 20'' base layer. In this embodiment, the 24'' end surface panels and the 22'' connection panels in the 20'' base layer have the same thickness. This model specifies a 40'' single step support block. Even with a single step support block 40, the flexibility of the pallet 10 to resist impacts from material handling equipment is significantly improved compared to a traditional wooden pallet.

The different levels of the first and second levels in the upper surface of the support blocks and the different levels of the first and second levels in the lower surface of the support blocks may be mixed and matched for a configuration not shown on the drawings. For example, the first level 48a' is below the second level 48b' in the stepped top surface of the support block as shown in Figure 5, but the first level 42a can be above the second level 42b as shown in Figure 4 .

The edges of each support block 40 extending between the base layer 20 and cargo layer 30 may be bent and/or angled as well shown in the top view of the support block in Figure 7. The inner face 46 of the support block 40 is inserted. In slot 50 of pallet 10, having angled edges 46a. The edges can range at 46a angles from about 25 to 75 degrees, for example, to provide the impact force to the forks of the forklift if such an impact were to occur. The edges shown are at a 45 degree angle.

The outer face 47 of the support block 40 faces away from the opening 50 of the pallet 10 and has angled edges 47a. Edges with corners have a radius of about 2 to 12 mm, for example, preferably about 4 to 8 mm. Markings 60 may also be applied to the outer side walls of the support blocks 40, as shown in Figures 1 through 3. Alternatively, the edges of the support blocks 40 can be all angled or all can be curved. Of course, the adjacent surfaces of the support block 40 defining an edge can be perpendicular to each other so that the edges are not curved or made at angles. Instead, the edges are tapered.

The pallet 10 also includes a plurality of intermediate support blocks 72 that are coupled between the base layer 20 and the cargo layer 32. Each intermediate support block 72 is located at the same level as the upper and lower surfaces to receive the two corresponding connection plates 22 And 32 of the base and cargo layers 20 and 30.

The intermediate support blocks 72 are rectangular in shape, as well shown in the top view of Figure 8. It is preferable for the width of each intermediate support block 72 to be the same as the width of the connection panels 22 and 32 in the base and cargo layers 20 And 30. The edges 74 of the intermediate support blocks 72 can resemble the edges of the support blocks 40. As shown in Figure 8, the edges are at angles at 45 degrees, for example.

Referring to Figures 9 and 10, strength plates 100'' can be used to increase the flexibility of the 10'' pallet with single step support blocks 40''. The 100'' gussets are coupled to the ends of the 22'' connector boards in the 20'' base layer. 100'' gussets can also be referred to as pin plates, and are particularly useful in distributing impact forces to the ends of the 22'' connection plates in the base layer of a 10'' pallet.

Each end of a 22'' breadboard in the 20'' base layer receives a 100'' backplane. For the 10'' pallet shown, each 22'' connection plate includes two 100'' strength plates for a total of four reinforcement plates per pallet. The 100'' gusset shown is made of foil a few millimeters thick, for example. Flanges were inserted into the foil to form projections 102'' extending outward from the bottom surface of the strength plate 100''. The upper surface shown of the gusset is free of any projections. However, the protrusions may also extend from the upper surface of the gusset in other embodiments.

Typically each reinforcement plate is 100'' wide with a width substantially equal to the width of a corresponding end of the 22'' bus plates in the base layer 20''. The width of the 100'' gussets can be less than the width of the corresponding ends of the 22'' gussets as long as the fasteners 106'' used to attach the end of the 22'' gusset to the bottom surface of the support block 40'' pass through the gusset 100'' '. This also applies to 100'' length of gussets.

A first set of fasteners 104'' is used to attach the ends of the end deck boards and the ends of the connector boards 32'' in the cargo layer 20'' to the top surface of the support blocks 40''. Steps are made on the upper surface shown for the 40'' support blocks. Although not stated, strength plates 100'' may be used for 32'' conductor plates in cargo layer 30''.

Likewise, a second set of fasteners 106'' is used to couple the ends of the end deck boards 24'', including the corresponding 100'' gussets, and the ends of the connector boards 22'' to the base layer 20''. With a bottom surface for support blocks 40''. The lower surface of the 40'' support blocks includes first and second zones located at the same level.

The ends of the connector boards 22'' and the corresponding 100'' gussets are coupled to a first bottom deck area, and the ends of the end deck boards 24'' are coupled to the second bottom deck area. The mounting means shown 104'' and 106'' are screws, which easily penetrate 100'' gussets. Other types of fixing methods may be used, such as screws, for example.

When the end deck boards 24'' in the base layer of the pallet 10'' receive an impact force, such as that coming from a material handling equipment, the impact force is transmitted from the end deck boards 24'' to the second fasteners 106''. 'At the ends of the connector boards 22''. Without the gussets 100'', the shock force is concentrated on the ends of the connecting plates, which in turn dissipate the shock to the second mounting means 106''. Typically, the ends of the 22'' pallets are the weak link in a 10'' pallet, and begin to separate when the impact force is great enough. When the ends of the 22'' conductor plates separate, the crack extends along the length of the plate. This eventually causes the wood to separate from the pallet, causing damage to the pallet. An advantage is that the 100'' backplanes prevent this from happening by strengthening the ends of the 22'' bus boards in the base layer. The transmitted shock force is now distributed around the gussets 100''.

But another feature of the invention is directed to optimizing the size and placement of the end deck boards 34 and intermediate deck boards 36 of the cargo layer 30 of the pallet 10. Determining the position and size of the end deck boards 34 and 36 in the cargo layer 30 provides a high percentage of coverage to support a wide range of products that can be placed on the bearing layer. These products are typically packed in shipping boxes, for example.

According to the optimization of the loading layer 30 of the pallet 10, the number and size of the intermediate surface panels 36 are reduced while complete corner support for common shipping box sizes is achieved. Referring now to Figures 9 and 10, two or more intermediate deck boards of varying size 36a and 36b and a specific pattern are used to fully support the shipping box corners of most common shipping box sizes 16'', 12'', 8'' and 6''. Shipping boxes of different sizes are indicated with the reference number 90.

The 36A intermediate surface panels are approximately 3 to 4 inches wide while the 36B intermediate surface panels are approximately 5 to 6 inches wide. End deck boards 34 range in width from about 3 to 4 inches.

As shown in the figures, the width of the end surface panels 34 is 4 inches, the width of the intermediate end panels 36a is 3.5 inches, and the width of the intermediate surface panels 36b is 5.5 inches. Alternatively, the end surface panels 34 can have the same width as the intermediate surface panels 36a or vice versa.

The pattern shown calls for two 3.5" (36A) top deck boards, then a 5.5" (36B) top deck board, then a 3.5" top deck board, then another 5.5" top deck board, then two Intermediate top deck boards 3.5 inches.

The overall pattern of the intermediate upper deck boards 36a and 36b with the end deck boards 34 defines an exposed outer surface for the cargo layer 30 with overall dimensions of 40 by 48 inches. The intermediate deck boards 36a and 36b are not limited to use with the support blocks described 40. In other words, the improved upper deck pattern applies to pallets using conventional support blocks. Furthermore, the improved upper surface pattern also applies to any typical pallet design with a cargo layer.

Many other modifications and models according to the invention will come to the mind of those skilled in the field by familiarizing themselves with the information contained in the previous descriptions and accompanying drawings. For example, the stepped block design is applicable to a one-piece molded upper deck and a one-piece molded lower deck using durable surface panels. Accordingly, it should be understood that the invention is not limited to the disclosed embodiments, and modifications and embodiments are intended to be included at the discretion of those skilled in the invention.