Pallet assembly

Abstract

A pallet assembly includes a top plate and a runner having four side surfaces. The pallet assembly includes a pallet integrated module mounted to the pallet assembly and configured to collect journey data for transmission to a cloud. The pallet assembly includes a load-force plate disposed between the top plate and the runner. The load-force plate is configured to increase load bearing capacity of the top plate while adding strength to the pallet assembly. An antenna for the pallet integrated module is integrated with the load-force plate. The pallet assembly includes multiple load blocks disposed between the load-force plate and the runner. The load blocks are symmetrically positioned such that a forklift can enter from any of the four side surfaces of the runner. The runner is disposed under the load blocks. The pallet assembly includes a coating material that protects shipment of products that require sanitary conditions.

Claims

1. A pallet assembly comprising: a top plate and a runner having four side surfaces; a pallet integrated module mounted to the pallet assembly and configured to collect journey data for transmission to a cloud; a load-force plate disposed between the top plate and the runner, the load-force plate being configured to increase load bearing capacity of the top plate while adding strength to the pallet assembly, an antenna for the pallet integrated module being integrated with the load-force plate; and a plurality of load blocks disposed between the load-force plate and the runner, the plurality of load blocks being symmetrically positioned such that a forklift can enter from any of the four side surfaces of the runner, the runner being disposed under the plurality of load blocks, wherein the pallet assembly includes a coating material that protects shipment of foodstuffs and other products that require sanitary conditions.

2. The pallet assembly of claim 1, further comprising dowels configured to locate the top plate, the plurality of load blocks, and the runner with respect to one another.

3. The pallet assembly of claim 1, wherein the coating material includes a polyolefin, a polyester, a polyurethane, a polyurea, an epoxy, a polyurea-polyurethane hybrid, or a combination thereof.

4. The pallet assembly of claim 1, wherein the coating material is configured to prevent mold, virus, bacteria, and fungus growth.

5. The pallet assembly of claim 1, wherein: the top plate is made of a first wood species, the runner is made of a second wood species, the load-force plate is made of a third wood species, the plurality of load blocks is made from load-block wood species, and the first wood species, the second wood species, the third wood species, and the load-block wood species are selected based on cargo to be transported, shipping industry requirements, and a weight reduction target.

6. The pallet assembly of claim 1, wherein the load-force plate has a cross-form configuration or X-form configuration.

7. The pallet assembly of claim 6, wherein the load-force plate has the X-form configuration.

8. The pallet assembly of claim 7 wherein: the load-force plate includes a first corner, a second corner, a third corner diagonally opposite the first corner, and a fourth corner diagonally opposite the second corner; and the X-form configuration defines a first support spanning from the first corner to the third corner and a second support spanning from the second corner to the fourth corner.

9. The pallet assembly of claim 1, wherein the antenna is embedded in the load-force plate.

10. The pallet assembly of claim 1, wherein the antenna is printed onto the load-force plate.

11. The pallet assembly of claim 1, wherein the antenna extends along the load-force plate.

12. The pallet assembly of claim 11, wherein: the load-force plate has a cross-form configuration that defines a first edge section, a second edge section, a third edge section, a fourth edge section, and a middle section; the middle section connects to the first edge section at a midpoint of the first edge section; the middle section connects to the second edge section at a midpoint of the second edge section; the middle section connects to the third edge section at a midpoint of the third edge section; the middle section connects to the fourth edge section at a midpoint of the fourth edge section; and the antenna extends from the first edge section, through the middle section, to the third edge section.

13. The pallet assembly of claim 11, wherein: the load-force plate has a cross-form configuration that defines a first edge section, a second edge section, a third edge section, a fourth edge section, and a middle section; the middle section connects to the first edge section at a midpoint of the first edge section; the middle section connects to the second edge section at a midpoint of the second edge section; the middle section connects to the third edge section at a midpoint of the third edge section; the middle section connects to the fourth edge section at a midpoint of the fourth edge section; the antenna is located in the first edge section; a second antenna is located in the third edge section; and the antenna and the second antenna electrically connect to the pallet integrated module via the middle section.

14. The pallet assembly of claim 13, wherein the load-force plate includes a hole in the middle section through which extend electrical connections from the pallet integrated module to the antenna and the second antenna.

15. The pallet assembly of claim 1, wherein the antenna is electrically distinct from the pallet integrated module and is configured to act as a signal repeater.

16. The pallet assembly of claim 1, wherein the antenna is electrically connected to the pallet integrated module.

17. The pallet assembly of claim 1, wherein the pallet integrated module is physically separated from the load-force plate.

18. The pallet assembly of claim 17, wherein the pallet integrated module is mounted to one of the plurality of load blocks.

19. The pallet assembly of claim 1, wherein the coating material includes a flame-retardant additive.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts an assembly view of the first preferred embodiment of the pallet assembly of the present invention.

(2) FIG. 2A depicts a layered top view depicting a top plate, a load-force plate, and a plurality of load blocks with aligning dowels symmetrically and equally positioned upon a runner of the first preferred embodiment of the pallet assembly of FIG. 1.

(3) FIG. 2B depicts a layered bottom view depicting the top plate, the load-force plate, the pallet integrated module, the nine (9) load blocks with aligning dowels symmetrically and equally positioned on the runner, and the pallet integrated module abutting the center load block of the first preferred embodiment of the pallet assembly of FIG. 2A.

(4) FIG. 3A depicts a layered top view depicting the top plate, the load-force plate (cross-form) with aligning dowels, the pallet integrated module, the nine (9) load blocks symmetrically and equally positioned on the runner and the pallet integrated module abutting the center load block of the first preferred embodiment of the pallet assembly of FIG. 2A.

(5) FIG. 3B depicts a layered top view depicting the top plate, the load-force plate (X-form), the pallet integrated module, the nine (9) load blocks with aligning dowels symmetrically and equally positioned on the runner and the pallet integrated module abutting the center load block of a second preferred embodiment of the pallet assembly of the present invention.

(6) FIG. 4 depicts an assembly view of the top plate of the pallet assembly of the present invention.

(7) FIG. 5 depicts an assembly view of the load-force plate having a cross-form configuration for the first preferred embodiment of the pallet assembly of the present invention.

(8) FIG. 6 depicts an assembly view of the load-force plate having an X-form configuration for the second preferred embodiment of the pallet assembly of the present invention.

(9) FIG. 7 depicts an assembly view of the runner for the first, and second preferred embodiments of the pallet assembly of the present invention.

(10) FIG. 8A depicts an exploded detail view of a load block for use in the first, and second preferred embodiments of the pallet assembly of the present invention.

(11) FIG. 8B depicts an exploded detail view of the pallet integrated module for the first and second preferred embodiments of the pallet assembly of the present invention.

(12) FIG. 9A depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention with antennas mounted in the load force plate (cross form) serving as a signal extender.

(13) FIG. 9B depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention with antennas mounted in the load force plate (cross form) serving as an antenna contact tracking sensor.

(14) FIG. 9C depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention with antennas mounted in the load force plate (cross form) serving as an antenna repeater where there is no electrical contact to the pallet integrated module.

(15) FIG. 10A depicts a flow chart for the antenna that is electrically connected to the pallet integrated module of FIG. 8B.

(16) FIG. 10B depicts a flow chart depicting the functioning of the antenna repeater that is printed onto or embedded into the load-force plate that acts like a signal repeater and is not directly connected to the pallet integrated module.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(17) Referring now to the drawings, FIGS. 1, 2A, and 2B depict the first preferred embodiment of the pallet assembly [10] of the present invention. The pallet assembly of the present invention [10] comprises a top plate [20], a load-force plate [30], a runner [60], a pallet integrated module [55], and a plurality of load blocks [50] disposed between the load force plate [30] and the runner [60].

(18) FIG. 2A depicts a layered top view depicting the top plate [20], the load-force plate [30], and a plurality of load blocks [50] with aligning dowels [70] symmetrically and equally positioned on the runner [60] of the first preferred embodiment of the pallet assembly [10] of FIG. 1.

(19) The outer surface of the pallet assembly of the present invention [10], the top plate [20], the load-force plate [30], and the runner [60] preferably have generally, square shapes. The load blocks [50] are symmetrically distributed about the pallet assembly [10] between the load-force plate [30] and the runner [60] such that a forklift (not shown) can approach the pallet assembly [10] from any of the four side surfaces thereof.

(20) FIG. 2B depicts a layered bottom view of the top plate [20], the load-force plate (cross form) [30], the pallet integrated module [55], the nine (9) load blocks [50] with aligning dowels [20] symmetrically and equally positioned on the runner. The pallet integrated module [55] abuts the center load block of the nine load blocks [50] of the first preferred embodiment of the pallet assembly [10] of FIG. 2A. The pallet integrated module [55] is preferably battery powered. The battery unit for the pallet integrated module lasts for the entire life of the unit. The pallet integrated module [55] also has antennas, microprocessors, and memory capability. The pallet integrated module [55] monitors temperature, mechanical shock, humidity, and time. The pallet integrated module [55] has a unique electronic identity programmed at the factory when the pallet is assembled. The pallet integrated module [55] also can be programmed at the customer's location, to identify the material that is on the pallet. This customer programming will be changed each time the pallet assembly of the present invention [10 and 110] makes a cycle from the loading location to the unloading location and back to the customer's loading location. The packaging of the pallet integrated module [55] is robust enough to survive contact with pallet jacks and forklifts.

(21) FIG. 3A depicts a layered top view depicting the top plate [20], the load-force plate (cross-form) [30], the pallet integrated module [55], the nine (9) load blocks [50] symmetrically and equally positioned on the runner [60] of the first preferred embodiment of the pallet assembly [10] of the present invention.

(22) FIG. 3B depicts a layered top view depicting the top plate [20], the load-force plate (X-form) [40], the pallet integrated module [55], the nine (9) load blocks [50] symmetrically and equally positioned on the runner [60] of the second preferred embodiment of the pallet assembly [110] of the present invention.

(23) FIG. 4 depicts an assembly view of the top plate [20] of the pallet assembly [10, and 110] of the present invention.

(24) FIG. 5 depicts an assembly view of the load-force plate [30] having a cross-form configuration for the first and second preferred embodiments of the pallet assembly [10 and 110] of the present invention.

(25) FIG. 6 depicts an assembly view of the load-force plate [40] having an X-form configuration for the second preferred embodiment of the pallet assembly [110] of the present invention.

(26) FIG. 7 depicts an assembly view of the runner [60] for the first and second preferred embodiments of the pallet assembly [10 and 110] of the present invention.

(27) FIG. 8A depicts an exploded detail view of a load block [50] for use in the first and second preferred embodiments of the pallet assembly [10 and 110] of the present invention.

(28) FIG. 8B depicts an exploded detail view of the pallet integrated module [55] for in the first and second preferred embodiments of the pallet assembly [10 and 110] of the present invention.

(29) FIG. 9A depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention with antennas mounted in the load force plate (cross form) [30] serving as a signal extender on the load-force plate (cross form) [30] of the first and second preferred embodiments of the pallet assembly [110] of the present invention. The upper antennas [34A and 34B] run parallel to each other and are embedded in the upper center bar [31] of the cross of the load force plate (cross form) [30] and the lower antennas [37A and 37B] run parallel to each and are embedded in the lower center bar [32] of the cross of the load force plate (cross form) [30].

(30) The load force plate depicted in FIG. 1A is the cross-form load force plate [30]. However, it is understood that one skilled in the art can readily apply the principles of the signal extender of FIG. 9A to the load-force plate (X-form configuration) [40].

(31) FIG. 9B depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention with antennas mounted in the load force plate (cross form) [30] serving as an antenna contact tracking sensor on the load-force plate (cross form) [30] of the first and second preferred embodiments of the pallet assembly [10 and 110] of the present invention. The upper antennas [34A and 34B] run parallel to each other and are embedded in the upper center bar [31] of the cross of the load force plate (cross form) [30] and the lower antennas [37A and 37B] run parallel to each other and are embedded in the lower center bar [32] of the cross of the load force plate (cross form) [30]. The antennas [34A and 34B] and [37A and 37B] formed in the load force plate (cross form) [30] drop down into a hole formed at the juncture of the cross to contact the tracking sensor, which is the pallet integrated module [55].

(32) The load force plate depicted in FIG. 9B is the cross-form load force plate [30]. However, it is understood that one skilled in the art can readily apply the principles of the signal extender of FIG. 9B to the load-force plate (X-form configuration) [40].

(33) FIG. 9C depicts a detailed view of the first preferred embodiment of the pallet assembly of the present invention [10] with antennas mounted in the load force plate (cross form) [30] serving as an antenna repeater where there is no electrical contact to the tracking sensor (pallet integrated module [55]).

(34) The antenna repeaters [38A and 38B] are embedded in and run parallel to each other in the center bar of the cross of the load force plate (cross form) [30] and make no electrical contact with the pallet integrated module (tracking sensor) [55].

(35) The load force plate depicted in FIG. 9C is the cross-form load force plate [30]. However, it is understood that one skilled in the art can readily apply the principles of the signal extender of FIG. 9C to the load-force plate (X-form configuration) [40].

(36) FIG. 10A depicts a flow chart for the antenna that is electrically connected to the pallet integrated module of FIGS. 9A and 9B.

(37) FIG. 10B depicts a flow chart depicting the functioning of the antenna repeater that is printed onto or embedded into the load-force plate, that acts like a signal repeater, and is not directly connected to the pallet integrated module.

(38) The coating is smooth, which enables a more thorough cleaning. There is no place for dirt, bacteria, mold, fungus, microbes, or viruses to hide.

(39) Another advantage of the pallet assembly [10 and 110] of the present invention is that the species of wood selected for the pallet assembly [10 and 110] varies and is dependent upon the cargo being transported. Different species of wood [80, 81, 82, 83] are selected for the top plate [20], the load-force plate [30 or 40], the plurality of load blocks [50], and the runner [60] depending upon the weight of the cargo, respectively. By changing the species of wood, the strength and weight of the pallet assembly can be configured to meet the requirements of the customer. If the customer is shipping steel or cast parts, the strength of the pallet components must be reconfigured to accommodate the weight of these parts. In this example, the pallet components, a dense wood such as Baltic Birch or oak is used. If the customer is shipping a light load, such as a child's game or toy, a less dense wood, such as pine is selected. As the wood species are changed, the pallet cost and weight can be reconfigured to meet the requirements of the shipping industry while also meeting the needs of the customer for weight reduction and cost. All our additives are of such a small micron size, they don't cause the polyurea to be off from ratio. Off ratio polyurea will not cure properly and will not have all the properties of a properly cured polyurea.

(40) Dowels, preferably wooden, are used to accurately locate the top plate, the legs, and the bottom plate within very tight tolerances. The pallet of the present invention can be readily assembled with the wooden dowels that facilitate attachment of transverse deck boards to parallel stringers in a quick and efficient manner. Also, the dowels provide structural stability during the adhesive curing and prevent rotation of the blocks during assembly. This build technique enables tight tolerances between all the components. For this equipment to properly pick and lift the pallet, the pallet must be built to tight tolerances.

(41) The pallet integrated module [55] collects journey data on location, temperature, humidity, and shock along with “store forward” capability during unconnected times of the journey. All this data is sent to the cloud for parsing, future queries, report generation and alert capability. The module is capable of “over the air” software upgrades and has various modes of connectivity not only to mitigate connectivity costs but to seamlessly interact with the complete ecosystem.

(42) The pallet integrated module [55] is programmed and then the pallet assembly of the present invention is sent to the customer who is renting or leasing the pallet. Information about the contents of the pallet is programmed into the electronics at the location of the customer. During shipping, the electronics monitors, temperature, G force, humidity, and other elements versus time. This data can be accessed at various places along the shipping route. The data collected helps ensure that contents of the pallet assembly of the present invention are not exposed to inappropriate temperatures or other harmful environmental conditions. The data also helps to prove that the pallet contents were properly cared for during shipping. The top plate [20], the load-force plate [30 and 40], the load blocks [50], and the runner [60] are preferably joined with an adhesive.

(43) Suitable polymeric materials include, but are not limited to, polyolefins, polyesters, polyurethanes, polyureas, epoxies, polyurea-polyurethane hybrids, and combinations thereof. Desirably, the polymeric material comprises polyurea, polyurethane, or a combination thereof (see for example U.S. patent application Ser. No. 09/399,271 entitled “Novel Pallets” (Phillips; et al.).

(44) The pallet assemblies [10, and 110] of the present invention are comprised of a conventional pallet coated with a fast-curing elastomeric material using spray techniques whereby a homogeneous, non-porous, and monolithic coating is formed. The desired elastomeric materials used are prepared by initiating the reaction of an aliphatic or aromatic isocyanate-terminated compound or polymer with an aliphatic or aromatic amine-terminated compound or polymer immediately before applying the elastomeric material to the surface to be coated. Desirably, the reactive components (i.e., isocyanate-containing and amine-containing materials) are mixed directly in a spray gun used to apply the elastomeric material. The thickness of the elastomeric coating can easily be controlled by conventional application means. It is important that the thickness of the elastomeric coating be enough so that the coating is resistant to impact that is normal in use. The desired thickness of the elastomeric coating on the pallet material is between approximately 1 mm and 250 mm, with the most desired thickness of between 60 mm and 75 mm.

(45) The pallet assemblies of the present invention comprise one or more polymeric materials optionally in combination with one or more filler materials. Suitable polymeric materials include any polymeric material capable of being formed into a polymeric board or sheet. Suitable polymeric materials include, but are not limited to, polyolefins, polyesters, polyurethanes, polyurea, epoxies, polyurea-polyurethane hybrids, and combinations thereof. Desirably, the polymeric material comprises polyurea, polyurethane, or a combination thereof. More desirably, the polymeric material comprises a polyurethane foam. The filler material may be organic or inorganic filler material in the form of particulate material, fibers, fabrics, rods, or any other structural reinforcement. Suitable inorganic filler materials include, but are not limited to, calcium carbonates, clays, silica, sand, glass fibers and carbon fibers. Suitable organic fillers include, but are not limited to, fibers such as cotton, rayon, nylon, and other polymeric fibers, such as polyolefin fibers and aramid fibers.

(46) The deflection, stress, strain testing of the load-force plate (cross-form) best compared to X-FORM load force plate (X-form) and the standard pallet. ISO 8611 Rack Test Simulation (2750 lb.) were conducted, and the results are shown below:

(47) Deflection Testing:

(48) The standard pallet performed well. The deflection was 100 mm before the 2750 lb. load was applied. The deflection was 87.39 mm after the 2750 lb. load was applied.

(49) The load-force plate (X-form) performed better. The deflection was 100 mm before the 2750 lb. load was applied. The deflection was 93.98 mm after the 2750 lb. load was applied.

(50) The load-force plate (cross-form) performed best. The deflection was 100 mm before the 2750 lb. load was applied. The deflection was 94.35 mm after the 2750 lb. load was applied.

(51) Stress Testing:

(52) The standard pallet performed well. The stress was 8.522e{circumflex over ( )}+7 after the 2750 lb. load was applied.

(53) The load-force plate (X-form) performed better. The stress was 6.114e{circumflex over ( )}+7 after the 2750 lb. load was applied.

(54) The load-force plate (cross-form) performed best. The stress was 5.822e{circumflex over ( )}+7 after the 2750 lb. load was applied.

(55) Strain Testing:

(56) The standard pallet performed well. The stress was 5.648e{circumflex over ( )}−03 after the 2750 lb. load was applied.

(57) The load-force plate (X-form) performed better. The stress was 3.943e{circumflex over ( )}−03 after the 2750 lb. load was applied.

(58) The load-force plate (cross-form) performed best. The stress was 3.688e{circumflex over ( )}−03 after the 2750 lb. load was applied.

(59) The pallet assembly of the present invention is designed to meet the requirements of the customers, as well as international standards for strength, flex, flame, and smoke requirements. The thin top plate, the load-transfer plate, the support blocks, and the runner will all be coated in a spray or a dip coating (powder coating or fluid bed coating) to protect the wood and to add strength to the pallet assembly of the present invention.

(60) Throughout this Application, various Patents and Applications are referenced by number and inventor. The disclosures of these documents in their entireties are hereby incorporated by reference into this specification in order to more fully describe the state of the art to which this invention pertains.

(61) It is evident that many alternatives, modifications, and variations of the pallets of the present invention will be apparent to those skilled in the art in lieu of the disclosure herein. It is intended that the metes and bounds of the present invention be determined by the appended claims rather than by the language of the above specification, and that all such alternatives, modifications, and variations which form a conjointly cooperative equivalent are intended to be included within the spirit and scope of these claims.

PARTS LIST

(62) 10. Pallet Assembly (1.sup.st preferred embodiment) 20. Top Plate 30. Load-Force Plate (Cross-Form configuration) 31—Upper Center Bar 32—Lower Center Bar 34A and 34B. Upper Antennas 36. Hole in Load-Force Plate 37A and 37B. Upper Antennas 38A and 38B. Antenna Repeater 40. Load-Force Plate (X-Form configuration) 50. Load Block 55. Pallet Integrated Module 60. Runner 70. Dowel 110. Pallet Assembly (2.sup.nd preferred embodiment)