Pallet and logistic system

Abstract

A pallet has a deck, a skid and a plurality of blocks, spacing the skid from the deck. The blocks comprise spacer portions and sleeve portions, wherein the sleeve portions may extend above and below the spacer portions. The pallet constructed in this way can advantageously be made in any conventional size to meet the relevant norm or standard, while benefitting from the fact that the sleeve portions protect the edges of the deck and/or skid from impact. Furthermore, any impact imparted on the blocks is transmitted by the respective sleeve to the deck and/or skid. A logistic system is also described.

Claims

1. A pallet, comprising: a deck, having a deck upper surface, a deck lower surface and a deck peripheral edge; a skid, having a skid upper surface, a skid lower surface and a skid peripheral edge; and a plurality of blocks, spacing the skid from the deck, the blocks comprising spacer portions and sleeve portions; wherein the sleeve portions extend above and below the spacer portions to form a continuous planar surface with the deck upper surface and skid lower surface, wherein the deck, the skid and the blocks are each individually coated with a cured resin coating; wherein the deck, the skid and the blocks are individually connected to each other by means of an adhesive; and wherein the cured resin has a tensile strength Tresin and the adhesive has a tensile strength T.sub.adhesive such that T.sub.resin>T.sub.adhesive.

2. The pallet according to claim 1, wherein the sleeve portions extend to level with the deck upper surface and the skid lower surface outside peripheral edges of the deck and the skid.

3. The pallet according to claim 1, wherein the deck and/or skid peripheral edges are chamfered in the regions between the blocks to assist fork entry.

4. The pallet according to claim 1, wherein the resin is a polyurea resin; a polyurethane resin; a polyaspartic resin; an epoxy resin; a polyurethane-polyurea hybrid resin; or a mixture thereof; and Wherein the adhesive is a two-component modified silane, elastic adhesive.

5. The pallet according to claim 4, wherein the resin coating has a thickness of from 0.5 mm to 1.5 mm.

6. The pallet according to claim 1, wherein the deck comprises a skin-core construction and the deck peripheral edge comprises an edge member having a width that is at least twice as great as a width of the sleeve portions; and wherein the deck peripheral edge is provided with a protective bumper.

7. The pallet of claim 1, further comprising an electronic tag containing data identifying the pallet.

8. The pallet of claim 7, wherein the electronic tag contains a wireless radio chip operating under a low power sensor network protocol such as WiFi, Bluetooth, Zigbee, Z-wave, BlueRobin and the like: wherein the electronic tag further comprises a 3G/4G/5G/LTE, LoRa, Sigfox or other LPWAN modem chip; and wherein the electronic tag transmits a ping signal to a receiver or gateway device at adjustably programmable intervals.

9. The pallet according to claim 7, wherein the electronic tag is provided with a sensor to detect ambient conditions selected from the group consisting of: temperature, humidity, light, UV radiation, CO2, and hazardous gas.

10. The pallet according to claim 7, wherein the electronic tag is provided with memory in order to store measurements and events.

11. The pallet according to claim 7, wherein the electronic tag is provided with a weight sensor, preferably located and mounted in or on the middle block, for detecting a load on the pallet; and wherein the electronic tag is provided with an activity monitor for detecting movement of or impact on the pallet.

12. A method of tracking a pallet having an electronic tag according to claim 7, the method comprising receiving information by wireless transmission from the electronic tag to a receiver.

13. The method according to claim 12, wherein the tag includes an activity monitor sensor for determining whether the pallet is in movement and the frequency at which information is transmitted is adjusted based on the presence or absence of movement; wherein the tag includes an impact sensor and information relating to the time and degree of impact on the pallet is stored and subsequently transmitted to the receiver; and wherein the tag includes a temperature sensor and information relating to excessive temperatures is stored and subsequently transmitted to the receiver.

14. The method of claim 13, further comprising providing a gateway device and transmission from the electronic tag to the receiver takes place via the gateway device; wherein the gateway device is provided in or on a master pallet and the pallet and the master pallet are transported together; and wherein the gateway device comprises a wireless radio chip and a 3G/4G/5G/LTE modem chip.

15. The method according to claim 13, wherein information transmitted from the tag is stored in an internet database (cloud) and processed via smart algorithms so that the optimal routing of pallets can be determined and implemented.

16. A method of manufacture of the pallet according to claim 1, comprising providing a barcode to a first side of the pallet, generated from an computer system, and subsequently providing the other three sides of the pallet with the barcode, whereby the barcode on the first side is read with an optical scanner and then copied onto the other three sides of the pallet.

17. A method of repairing the pallet according to claim 1 when one or more of its elements is damaged, the method comprising: removing a damaged element by cutting through the adhesive connecting the damaged element to a neighbouring element; connecting a replacement element to the neighbouring element by means of adhesive.

18. The method of claim 17, wherein cutting through the adhesive takes place using a cutting wire; and comprising removal of the sleeves prior to cutting through the adhesive.

19. A pallet logistic system comprising: a pluralilty of pallets according to claim 1, each provided with an electronic tag capable of emitting a periodic communication signal (ping signal) containing data relating to that pallet; a plurality of gateways, arranged to receive the ping signals from pallets that are within range and transmit the data to a publically accessible network; a logistic management application running on a programmable device, the logistic management application enabling a user to extract the data from the network and analyse the data to determine individual and collective information regarding the plurality of pallets.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features and advantages of the invention will be appreciated upon reference to the following drawings of a number of exemplary embodiments, in which:

(2) FIG. 1 shows a perspective view of a pallet according to the present invention;

(3) FIG. 2 shows the pallet of FIG. 1 in exploded perspective view;

(4) FIG. 3A shows a detail III A of the pallet of FIG. 1 in partially cut-away view;

(5) FIG. 3B shows a cross-sectional view at III B of the pallet of FIG. 1;

(6) FIG. 4 shows a schematic view of the architecture of an electronic tag for use in the invention;

(7) FIG. 5 shows a schematic view of a pallet logistic system according to the invention;

(8) FIG. 6 shows a pallet according to the invention with side walls; and

(9) FIG. 7 shows a detail of FIG. 6.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

(10) FIG. 1 shows a perspective view of a pallet 1 according to the present invention in its ready to use state. The illustrated pallet is of conventional EuroPallet dimensions (1200 mm×800 mm×144 mm). It includes a deck 10 having a deck upper surface 12 a deck lower surface 14 and a deck peripheral edge 16. Blocks 20 are provided beneath the deck 10 and space the deck 10 from a skid 30. The skid 30 also has a skid upper surface 32 a skid lower surface 34 and a skid peripheral edge 36. Openings 4 between the blocks 20 allow the forks of a fork lift truck to be inserted under the deck 10 to engage the deck lower surface 14 for lifting the pallet 1 as is otherwise conventional.

(11) Unlike conventional pallets, the blocks 20 are provided with sleeve portions 22 that extend upwards, covering the deck peripheral edge 16 to a position level with the deck upper surface 12. The sleeve portions 22 also extend downwards and overlap the skid peripheral edge 36. Furthermore, it may be seen that the deck peripheral edge 16 and the skid peripheral edge 36 are provided with chamfers 17, 37 at the location of the openings 4. This facilitates access by a fork-lift and reduces any damage due to the fact that an impact may be deflected. A barcode 52 is provided on block 20. In practice, the barcodes 52 will be placed on the diagonally opposing blocks 20, one on each external face (i.e. 4 barcodes 52 to each pallet).

(12) FIG. 2 shows the pallet 1 of FIG. 1 in exploded view whereby the individual elements that form the pallet 1 can be better seen. Turning first to the deck 10, it can be seen that the deck peripheral edge 16 has cutaway regions 18 at the corners and in the middle of each side. Between the cutaway regions 18 are the chamfers 17. In this embodiment, the deck peripheral edge 16 is either cutaway or chamfered around the full periphery although it will be understood that these regions may be spaced from each other.

(13) There are in total nine blocks 20A-I, of which all except the central block 20E, comprise sleeve portions 22 and spacer portions 24. The central block 20E comprises only a spacer portion 24. The corner blocks 20A, 20C, 20G and 20I all have angled sleeve portions 22, while the side blocks 20B, 20D, 20F and 20H in the middle of each side, have straight sleeve portions 22. The sleeve portions 22 all extend above the respective spacer portion 24 by a distance that corresponds to the thickness of the deck 10 and have a width that corresponds to a depth of the cutaway regions 18. This ensures that the deck 10 can be recessed into the sleeve portions 22 with an exterior surface of the sleeve portions 22 being co-linear with the deck peripheral edge 16. The central block 20E comprises a cavity 26 in which is located an electronic tag 60. The tag 60 is a proprietary electronic active RFID chip-based, track and trace device with incorporated battery, capable of transmitting over ranges of up to 300 metres, available from BM Innovations GmbH under the name BlueRobin™, operation of which will be described in further detail below. Other similar devices such as Bluetooth low power (BLE) devices may also be used.

(14) The skid 30 is similar in terms of the skid peripheral edge 36, which has cutaway regions 38 at locations corresponding to the blocks 20. The parts of the skid peripheral edge that are not cut away are chamfered at chamfers 37. In the disclosed embodiment, the deck 10 is closed but it will be understood that open or apertured decks may be used as appropriate. The illustrated skid 30 is a five member skid having first, second and third skid members 30A-C and front and back braces 30D, E. The skid 30 may be of conventional wooden construction with the skid members 30A-E being glued and pegged together in conventional manner. Alternatively, the whole skid may be of MDF or the like unitary construction. In the illustrated embodiment, all of the skid members 30A-E have chamfers on all sides. It will be understood that chamfering can also be limited to just the skid peripheral edge 36.

(15) FIG. 3A shows an enlarged partially cut-away view of detail III A, and FIG. 3B shows an enlarged cross-section at III B in FIG. 1. According to this view, the deck 10 and part of the block 20I have been cut away to show the pallet construction. The deck 10 comprises an outer skin 11 of wood, covering an inner core 13 formed from slats of MDF material. In the illustrated embodiment, the skin 11 has a thickness of 3 mm. It will be understood that the outer skin may also be made of plywood, MDF or even of a composite e.g. laminated with fibre reinforced layers. Edge members 15, also of MDF, form the peripheral edge 16. These edge members 15 have a depth of 22 mm corresponding to the thickness of the core 13 and a width of 30 mm. This width is sufficient to allow cutaway regions 18 of around 15 mm, without unduly weakening the structure of the deck. The whole of the deck 10 is coated with a polyurethane resin coating 40, having a thickness of around 1 mm. The coating 40 provides a number of advantages to the pallet. Not only does it make the deck 10 stronger and more impact resistant but it is also waterproof, easily washable, anti-slip and can be used to provide a desirable colour or look.

(16) The blocks 20 are also provided with the same coating 40 as the deck 10. They are glued to the deck 10 using an adhesive 42 that forms a relatively thick elastic bond between the elements. In the present embodiment, TEROSON MS 9399™ is used, which is a two-component modified silane adhesive available from Henkel. An advantage of this adhesive is that it remains elastic even after curing and, while being sufficiently strong to prevent undesired separation, ensures shock absorption in case of impact on the pallet 10. The adhesive joint can also be easily broken using a cutting wire.

(17) The skid 30 is also provided with the same coating 40, which covers it entirely. Adhesive 42 connects the skid 30 to the blocks 20. Also visible in this view are bumpers 44 provided on chamfers 17, 37 of the deck 10 and skid 30 respectively. The bumpers 44 are HDPE strips that are glued to and cover the chamfers 17, 37. Although not visible in this view, the bumpers 44 may be recessed into the material of the deck peripheral edge 16 and skid peripheral edge 36 respectively.

(18) In production, the deck 10, blocks 20 and skid 30 are individually manufactured in the form as shown in FIG. 2. The finished elements are then all coated with coating 40 prior to assembly. Electronic tag 60 is installed in the cavity 26 of the central block 20E and initialised. The tag 60 is battery powered and designed to operate for a period of up to 10 years based on normally expected usage. The blocks 20 are then adhered to the skid 30 using the adhesive 42 followed by application of the deck 10 with further adhesive 42 being placed onto the spacer portions 24 of the blocks 20. Once assembled, the tag 54 is sealed within the cavity 26 and can only be accessed in case of necessity by removal of the central block 20E. The bumpers 44 are then glued to over the chamfers 17, 37 and the barcode 52 is applied. Since it is desirable to have the same unique barcode 52 visible from each side of the pallet, application of the barcode preferably takes place by computer generation of a unique serial number for application as a barcode 52 to a first of the sides e.g. on block 20A. At subsequent locations in the automated production, the barcode 52 on block 20A may be read by an optical scanner and duplicated onto the other corner blocks 20C, 20G and 20I.

(19) In use, the sleeve portions 22 and the bumpers 44 fully protect the deck peripheral edge 16 and the skid peripheral edge 36 from any lateral shock due e.g. to incorrect insertion of a fork-lift into openings 4. In the case that damage does occur to the pallet 1, the elements that are damaged may be removed from the pallet 1 and replaced. In the case of damage to a single block 20, this may be removed by use of a wire cutter to cut adhesive 42 and separate the block 20 from the deck 10 and skid 30. This may involve first the removal of the sleeve portion 22 e.g. by cutting it away from the spacer portion 24. If the deck 10 or skid 30 is damaged, removal of all sleeve portions 22 may be desirable in order to conveniently cut away the blocks 20.

(20) FIG. 4 gives a schematic overview of the architecture of electronic tag 60. Tag 60 includes a processor 61, a battery 62 an input-output device 63, antenna 64, memory 65 and clock 66, which operate in a conventional manner to enable the tag 60 to communicate over distances of up to 300 metres with a suitably arranged receiver according to standard protocols including Bluetooth, Wi-Fi, Zigbee, Zensys, LoRa, 6LoWPAN, 433 Mhz/868 Mhz/915 Mhz, 3G/4G/5G/LTE proprietary protocols or any other low power wide area network protocols.

(21) The tag 60 is additionally provided with a temperature sensor 67, an accelerometer 68 and a weight sensor 69, all of which communicate with the processor 61. It will be understood that other sensors may also be included as required. In the case of the weight sensor 69, this is installed beneath the central block 20E and is calibrated during production to give a reading reflecting a distributed load supported on the deck 10. If required other calibrations may be applied depending on the nature of the product to be transported.

(22) FIG. 5 gives a schematic overview of a pallet logistic system 100 according to one aspect of the invention. The system 100 comprises a plurality of pallets 1, a receiver 110, a network data server 120 and a customer server 130. The receiver 110, network data server 120 and customer server 130 are linked to each other through the Internet 140 and have Cloud data storage. The system 100 also includes a master pallet 1′. The pallets 1 are as described above, each of which including a respective electronic tag 60. The master pallet 1′ is otherwise identical to the pallets 1, with the exception that it includes additional communication capability in the form of a gateway device 70 having a 3G modem chip enabling it to communicate directly with a telecom provider. It will be understood that other levels of communication may be equally applicable including 4G, 5G, LTE or other. The gateway device 70 is also enabled to interrogate the tags 60 of any normal pallets 1 that are within range.

(23) Operation of the system 100 will further be described with reference to FIGS. 4 and 5. In normal operation, the tags 60 on pallets 1 communicate wirelessly with the receiver 110 to the extent that they are in range. This may be the case when they enter or exit a warehouse facility, whereby the receiver 110 is located at an entrance or exit. The receiver 110 may also be mobile, e.g. located onboard a lorry, train or vessel. The tags 60 are set to ‘ping’ or emit a signal containing status information at predetermined times. This time period varies according to the status of the pallet 1. If the pallet 1 is stationary, as determined by the accelerometer 68, the tag 60 pings every 60 minutes. If the accelerometer 68 detects motion of the pallet 1, the processor 61 instructs the input-output device 63 to ping every 60 seconds. In this manner, the life of battery 62 is preserved (these ping times are exemplary and may be varied according to the requirements of the situation).

(24) The ping signal contains information stored by the memory 65 since the last communication with an external source. This may include data collected from the temperature sensor 67, the accelerometer 68 and the weight sensor 69, all of which is time stamped based on the clock 66 and provided with the pallet unique identity based on the barcode serial number 52. In this manner, complete data relating to the environment in which the pallet 1 has found itself can be recorded and subsequently transmitted. The ping signal is received by receiver 110, which acts as a gateway, for further transmission of the information to the internet 140. All this data is stored in the network data server 120, which will be used by the operator for operating the pallet pool. This network data server 120 will have the possibility to make available, via an Application Programming Interface or API, customer specific subsets of this data to customer servers 130 for use in their own IT systems.

(25) In an alternative mode of operation, the gateway device 70 on the master pallet 1′ is able to receive the ping signal from the pallets 1 when they are within range. This may be the case if the master pallet 1′ is present in a consignment of normal pallets 1. In that case, the gateway device 70 may be able to continuously communicate data from the pallets 1 throughout their journey. The gateway device 70 can transmit this data directly to the internet 140.

(26) It will be understood that based on the above system 100, the data that can be made available to the network data server 120 and the customer server 130 is limitless. Not only can data be generated in bulk relating to all pallets 1 within the system 100 but also individual data can be generated regarding the status of a particular pallet 1 and its load. The momentary position of a pallet 1 and its previous trajectory can be determined as can the environmental conditions (in this case temperature) to which it has been exposed. Additional sensors may be provided for all other detectable conditions that may be of interest. The condition of a pallet 1 may be determined by identifying sudden shocks or excessive loading using the respective accelerometer 68 and load sensors 69. This may be used to plan periodic maintenance or checks. Additionally, an individual pallet 1 may be interrogated by scanning the barcode 52 to directly determine its status. In this case, the barcode 52 allows an enabled mobile device such as a smartphone to extract data from the Internet 140 relating to recently received information transmitted from the tag 60 on the pallet 1.

(27) FIG. 6 shows a pallet 1 according to the invention with side walls 72. The pallet 1 with four side walls 72 form a so called box pallet 71. The pallet 1 of the invention is particularly suitable for building the box pallet 71. The reason is the sleeve 22 is simply extended vertically upward as shown. The extended sleeve 22 strength to the box construction. The sleeve 22 and side wall 72 are attached to one another in any suitable way for example by glueing.

(28) FIG. 7 shows a detail of FIG. 6 in that a cross section is taken close to a corner of the box pallet 71. The deck 10 rests on a block 20. A slot 73 is arranged in the upper side of the deck 10. A side wall 72 extends partly into the slot 73 in order to give additional strength to the pallet box 71.

(29) Thus, the invention has been described by reference to certain embodiments discussed above. It will be recognized that these embodiments are susceptible to various modifications and alternative forms well known to those of skill in the art. In particular, the pallet may be distinct from the schematically illustrated design.

(30) Many modifications in addition to those described above may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, these are examples only and are not limiting upon the scope of the invention.