Structural Element

Abstract

A structural element (10) for forming a panel, with an upper plane (12) and lower plane (14) which are parallel and deformed along their plane at intervals by pods (16) which extrude toward the opposing plane with their internal faces mating to of another.

Claims

1. A structural element made from sheet material that is deformed at intervals along its length and width to provide pods that protrude from the plane of the sheet, wherein at least two sheets are formed with such pods, and two of the sheets are juxtaposed to each other in mirror-image, or facing, fashion, with the pods being inwardly oriented and floors of the pods engaging in contact zones, such that the walls of the pods in both sheets slope obliquely relatively to the plane of their respective sheet, and the pods act as interconnecting diagonal braces whereby loads on the structural element will be transmitted along the surfaces of the pods in multiple directions and distributed throughout the structural element, the pods in each sheet having a close proximity to one another in order to be mechanically interdependent and so that the walls of engaged pods form diamond beam formations between adjacent engaged pods such that multiple diamond beam structures are formed by the diamond beam formations in the structural element in the negative spaces immediately between pairs of engaged pods, the slope of the walls of the diamond beam formations being straight between outwardly oriented, rounded, apexes of the diamond beam formations and the floors of the inwardly oriented pods.

2. A structural element in the form of a structural panel, the structural element comprising two outer sheets that act as the tensile and compression chords, with the two outer sheets comprising multiple inwardly orientated pods throughout the structural panel, the inwardly oriented pods having pod apexes that are joined together, which pods have a close proximity to one another in order to be mechanically interdependent creating a double depth space-frame lattice type matrix where loads placed on a surface of the structural panel are resisted and transferred through the chords and with the inwardly oriented pods acting as interconnecting diagonal braces such that the loads are transmitted along the surfaces of the pods in multiple directions and distributed throughout the structural element, wherein the walls of a side cross-section of joined pods, due to the close proximity of the pods in each outer sheet, form diamond beam formations between adjacent joined pods such that multiple diamond beam structures are formed by the diamond beam formations in the structural element in the negative spaces immediately between pairs of joined pods, the walls of the diamond beam formations being straight between outwardly oriented, rounded, apexes of the diamond beam formations and the pod apexes of the inwardly oriented pods.

3-7. (canceled)

8. A structural element according to claim 1, wherein a part of the floor of one or more of the pods is removed leaving an open annular flange.

9-11. (canceled)

12. A structural element according to claim 1, wherein the mouths of the pods are substantially square.

13. A structural element according to claim 12, wherein the pods occupy substantially the whole of a first of the two sheets, just leaving a grid for that first sheet where the pods meet at their upper edges.

14-15. (canceled)

16. A structural element according to claim 1, wherein away from the outwardly oriented, rounded, apexes of the diamond beam formations, the pods leave spaces between them in the material of the plane of the or each sheet around the pods.

17. A structural element according to claim 16, wherein the material of the plane of the sheet around the pods is provided with strengthening portions, such as corrugations, ridges or folds.

18-20. (canceled)

21. A structural element according to claim 1, wherein mouths of the pods are polygonal to create an elongated diamond beam structure along the walls of the engaged or joined pods.

22. The structural element of claim 1, wherein the pods have webbing at the corners of the pods.

23-24. (canceled)

25. A structural element according to claim 1, wherein the depths of the pods are in the range of 7 to 20 mm.

26. A structural element according to claim 1, wherein the sides of the pods are predominantly at an angle between 30 and 80 from the plane of the first or second surface of the structural element.

27-28. (canceled)

29. A method for producing a structural element comprising providing a sheet material, deforming deformed it at intervals along its length and width to provide pods that protrude from the plane of the sheet, providing a second sheet, deforming it at intervals along its length and width to provide pods that protrude from the plane of the second sheet, where the walls of the pods in both sheets slope obliquely relatively to the plane of their respective sheet, juxtaposing the two sheets such that the pods are inwardly oriented and juxtaposed to each other in mirror-image or aligning fashion and such that floors of the juxtaposed pods engage in contact zones, and joining the sheets in the contact zones to provide a unitary element, such that the pods act as interconnecting diagonal braces whereby loads on the structural element will be transmitted along the surfaces of the pods in multiple directions and distributed throughout the structural element, the pods in each sheet having a close proximity to one another in order to be mechanically interdependent and so that the walls of joined pods form diamond beam formations between adjacent joined pods such that multiple diamond beam structures are formed by the diamond beam formations in the structural element in the negative spaces immediately between pairs of joined pods, the walls of the diamond beam formations being straight between outwardly oriented, rounded, apexes of the diamond beam formations and the floors of the inwardly oriented pods.

30. A method according to claim 12, wherein the two sheets are deformed at the same time.

31. A method according to claim 12, wherein the deformation is a single pass pressing action.

32-68. (canceled)

69. A structural element according to claim 2, further comprising foam being positioned between the outer sheets to offer insulation or soundproofing properties.

70. A structural element according to claim 2, wherein the structural element is made from two sheets of a fibrous or cellulose material such as paper or card.

71. A structural element according to claim 2, further comprising a specifically identifiable material or element, or a chemical signature, within the identifiable material that forms the structural element.

72. A structural element according to claim 2, further comprising markings or watermarks on the inner surfaces of the outer sheets.

73. A structural element according to claim 2, further comprising a wireless, RFID, NFC, or electronic communication device incorporated therein to allow remote electronic identification.

74. A structural element according to claim 2, wherein the pod height does not exceed 10x the thickness of the outer sheets' material.

Description

[0086] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0087] These and other features of the present invention will now be described in further detail, purely by way of example, with reference to the accompanying drawings, in which:

[0088] FIG. 1 shows a perspective view of a first embodiment of structural element according to the present inventiona cut-away slice of a larger element;

[0089] FIG. 2 shows the structural element of FIG. 1 from a different angle;

[0090] FIG. 3 shows a sectional schematic of a diamond beam formed within the structural element of the present invention;

[0091] FIG. 4 shows a further sectional schematic of the structural element illustrating the action of forces acting on the structural element of FIG. 1;

[0092] FIG. 5 shows a further schematic of forces acting on the structural element;

[0093] FIG. 6 shows a perspective view of a space frame, illustrating the comparison between the present invention and a space frame, the comparison being useful for understanding the strength underlying the structural element of the present invention;

[0094] FIG. 7 shows a further schematic, in perspective view, illustrating force lines on a pod of the structural element of FIG. 1;

[0095] FIGS. 8A to 8C show side schematics of the variable thicknesses of a panel using two sheets and the pods of the present invention;

[0096] FIG. 8D shows how the strength of the structural element can be altered;

[0097] FIG. 8E shows how the shape of the panel may be other than flat;

[0098] FIGS. 9A to 9H show plan view schematics of various potential arrangements for the pods in a sheet of material used to form a structural element of the present invention. Other arrangements are also possible;

[0099] FIG. 10 shows a perspective view of part of an alternative structural element according to the present invention;

[0100] FIG. 11 shows a schematic perspective view of a cross-webbing in an embodiment of a structural element according to the present invention;

[0101] FIG. 12 shows a perspective view of a pallet incorporating a structural element according to the present invention;

[0102] FIG. 13 shows a perspective view of two pallets of FIG. 12 arranged such that they are nesting;

[0103] FIG. 14A shows an engineering drawing of legs of a pallet similar to that shown in FIGS. 12 and 13;

[0104] FIG. 14 B shows the leg on a pallet, with removable skids;

[0105] FIG. 15 shows a perspective view of two pallets of FIG. 12 arranged such that they are stacked, and only partially nested due to grooves in the surfaces of the structural element;

[0106] FIG. 16 shows a detailed view of the leg of a pallet of FIG. 12, plus some grooves for receiving a bottom of a leg of a further pallet;

[0107] FIG. 17 shows a side view of an alternative embodiment of pallet nested in an alternative arrangement to FIG. 13 to a ghosted second pallet;

[0108] FIG. 18 shows a perspective view of the pallet of FIG. 12 stood on a base plate;

[0109] FIGS. 19 to 21 show alternative uses for a structural element according to the present invention.

[0110] FIGS. 22 to 24 show a further usein the skids.

DETAILED DESCRIPTION OF THE INVENTION

[0111] Referring first of all to FIG. 1, a structural element 10 is shown. The structural element has sheets which form an upper plane 12 and a lower plane 14. These planes sit parallel to one another at a defined distance apart. On the surfaces of the upper plane 12 and lower plane 14 are circular holes 18. These circular holes 18 are present on both planes and are arranged such that they are in-line with the opposing circular hole 18 of the parallel plane. The circular holes 18 are arranged such that they sit in rows. Each row is offset with the row of circular holes 18 above it, such that alternative rows form a column of circular holes 18.

[0112] Although this specific description describes upper and lower planes, it should be appreciated that the planes may be replaced with curved sheets, thus they would then not be planar. For convenience, the word plane will nevertheless still be used.

[0113] Further, although circular holes are disclosed (and, later, square holes), other shapes of hole are also possible, including regular and irregular shapes.

[0114] Extending from the planes into the void formed between them, i.e. toward the opposing plane, are cones 16. These cones 16 define the pods and are circular in this embodiment, with the base of each cone 16 (in the planedefining the circular holes 18)defining a mouth for the cone that is circular (albeit with rounded edges).

[0115] The other end of the conethe apex of the cone 16, is truncated to form a frustum 20, the truncation being made parallel to the plane and the circular hole 18. Rounded edges, however, are again provided at that apex. The rounded edges reduce stress concentrations and provide a cleaner appearance.

[0116] The resulting frustum 20 of the cone 16, in respect of the upper plane, extends from the sheet defining the upper plane 12, and it will line up with the frustum 20 of a cone 16 extending from the sheet defining the lower plane 14. As such pairs of frustums 20 of pairs of cones 16 can mate to form a connection between the two planes with the circular holes 18 in each plane being aligned.

[0117] In FIG. 1 there is also shown to be a hole cut into the frustums 20 of the mating cones and the hole of one of the frustums has a lip 22 which extends as shown in FIG. 3 to allow a jointing, such as by crimping or welding, of the two frustums 20. The apex or frustum 20 of the two joined cones 16 are thus open at their middles and form a central circular hole 24. In this embodiment, since the mating cones are similar to one another (almost mirror images except for the lip 22), that circular hole 24 defines a medial plane, lying across a line parallel and equidistant to the upper plane 12 and lower plane 14.

[0118] Referring again to the cone in the upper sheet, the cone 16 is hollow, with, aside from the lip 22, the surface of the cone 16 laying generally along the line extending between the outer edge (the outer end of the rounded edges) of the frustum 20 and the circular hole 18 (inner end of its rounded edges) which forms the mouth. The area in which this surface lays, being a cone, can be referred to as the generatrix 32 of the respective pod.

[0119] There are a plurality of these cones, and in this embodiment they are provided in a regular array.

[0120] The sheets which form the upper plane 12 and lower plane 14, when forming a structural element 10, can form an enclosed panel by having a side edge 26. The side edge 26, in this embodiment, is a junction where the sheets of the upper plane 12 and lower plane 14 are folded toward one another such that they are no longer parallel and extend so that they meet or overlap thus forming an edge 26. Alternatively a side sheet can be attached to the edges of the sheet (either via, or to, folded flanges). However, it is preferred to use the sheets for the upper and lower planes since that reduces the component count of the final product.

[0121] Techniques for manufacturing the structural element and forming the cones 16 and edges 26 are discussed later in this document. However, suitable methods include press-forming or roll-forming, amongst others.

[0122] In FIG. 2, an alternative viewing angle is provided such that a row of cones 16 can be seen to have been vertically cross-sectioned, i.e. through from the upper plane 12 to the lower plane 14, to provide a view of the structure formed by the mated cones. Here it is seen that the sheet forming the upper plane 12 and the generatrix 32 of its cones 16 form a triangular shape along the cross-section line. The apex of this triangle is truncated to form a further frustum since the cones, and particularly circular holes 18 at their mouths, are spaced apart by a small percentage of the diameter of the circular holes 18 (in this example, about 11% of that diameter, although other embodiments may range from between 1 and 20%).

[0123] The base of this truncated triangular shape is abutted by the base of a similar truncated triangular shape formed by the sheet of the lower plane 14. The combination of these shapes is a shape similar to that of a diamond. Since this diamond shape extends parallel to the planes of the structural element (the panel), it forms a diamond beam 30. The diamond beam 30 is a result of the negative space left from the surfaces forming the cones 16 spanning the area between the upper plane 12 and lower plane 14.

[0124] There are similar diamond beams 30 formed throughout the structural element 10 in the space between the cones 16. In this embodiment, this is a honeycomb arrangement, and some of these are shown by centre lines 34. The centre lines 34 show the vertical axis of the diamond beam 30 between the apices of the upper 12 and lower 14 planes which are truncated. Since the circular holes 18 are arranged in a staggered arrangement in this example, the centre lines 34 define hexagonal cellsthe honeycomb structure. This is an efficient arrangement for the diamond beams. If the circular holes instead align in a grid, however, then the centrelines would likewise define a regular grid, with square angles, rather than 120 angles, between the beams.

[0125] For this embodiment, since the pods are round, the diamond beams 30 extend as shown with their geometries varyingdepending upon at which point along the beam thereof you are looking at within the grid or honeycomb of the structural element 10.

[0126] The side edge 26 is seen again in FIG. 2 and this again shows that where the edge of the structural element 10 is formed to form a panel, the cones 16 are not present in that zone of the sheet. As a result, no pod or cone is vertically truncated or otherwise distorted by the forming of the edges of the panel. This ensures that the diamond beams 30 are fully formed between all of the adjacent pairs of cones 16 and there is no weakened cone within the structural element. It also ensures that if edged panels are formed, then the edges of that panel will all be solid and smooth-walled. This can assist with functions such as the joining to other panels, forming a seal, or forming a smooth or regular edge for manual handling purposes.

[0127] Although the term diamond beam is used throughout the description of the invention, it is important to note that the geometry of the structural element is defined by various factors, such as manufacturing requirements, material choices, and visual geometry, i.e. the shapes of the pods, and as such it is a more complex shape than a strict replication of a geometric diamond beam. However, the resulting shape of the beams within the panel formed between the pods thereof, can nevertheless be effectively referred to as a diamond beam 30 since the created shape does share structural characteristics similar to those of a geometric diamond beam, recognising though the reduction in strength thereof resulting from the truncation of its apices.

[0128] A brief explanation of force loading within the beam as a result of loading applied to the panel, and thus also the diamond beam 30 of the present invention, is discussed below, with reference to FIGS. 3 to 7.

[0129] The diamond beams 30 created in the negative space throughout most of the structural element are important for the strength of the structural element 10.

[0130] Referring to FIG. 3, a single section through a diamond beam 30, similar to that which may be found in a structural element according to the present invention, is shown. The truncations at the apices are reduced compared to that of FIGS. 1 and 2 for the purpose of this illustration, which reduction can result from the circular holes 18 being packed more closely together, or from using other hole shapes or arrangements, such as the close-packed squares of FIG. 10.

[0131] In this example, force lines 40 are due to a compressive load on the upper plane 12 of the structural element 10 which is acting on the top apex of the diamond beam 30. The force lines 40 show the tendency of the load to act on the diamond beam 30 attempting to deform it by the resultant vertical forces and horizontal forces. To resist the horizontal forces opening the diamond beam, apex force lines 44 represent the bracing resistance to deflection from the upper plane 12 and lower plane 14 which joins a braces surface between the diamond beam 30 apices. Reactive force arrows 42 show the restraint afforded by the truncated edge 20, which in turn forms the edge of other diamond beams 30. Thus the force lines 40 acting horizontally to open this diamond beam 30, are being transferred to diamond beams 30 within the larger area of the structural element 10. The lip 22 also forms a level of bracing against the force lines 40 acting horizontally, since the lip 22 is a horizontal piece, and in this version it is double thickness, and with a crimped part providing a L-beam type formation, thus offering good resistance to flexure and bucking. The resistance to vertical deformation from a load represented by force lines 40 is granted by the bracing to the apex force lines 44 and restraint resulting in the reactive force arrows 42 since a vertical deformation would require a horizontal deformation. In addition, the lower plane 14 would transfer the forces to other diamond beams 30 within the structure, and give a resultant vertical force 46 resisting the load.

[0132] FIGS. 4 to 7 further show the transferral of the forces within the structural element 10 between cones 16 and diamond beams 30 which grant the structural element its strength and resistance to deformation.

[0133] The transferral of forces in such a manner can be compared to a space frame 60 as shown in FIG. 6. A space frame transfers loads along the length of the beams 62 of the space frame 60 such that a single point load acts on multiple beams 62.

[0134] A comparison of such a transfer to the structural element 10 of the present invention can be seen in FIG. 4, where diagonal force lines 50 represent the transferral of a load through a structure from upper apex 64 to lower apex 66 of adjacent diamond beams 30. The diagonal force lines 50 represent the typical beams 62 of a space frame 60.

[0135] The forces, in reality, would travel along and across the surfaces of the cones 16, to transfer a force between the upper plane 12 and lower plane 14, thus further spreading the loads. The area of force transferral 52 uses hashed lines to represent the area between diagonal force lines 50 and the route which the force would travel along the surface of a cone 16 if subjected to such a load. This force transferral can be seen in FIG. 7 where the area of force transferral 52 is shown not to follow a single diagonal force line 50, but travel along the surface of the cones 16. This shows the equivalence of the transferral of forces in the structural element 10 of the present invention compared to a space frame 60.

[0136] Referring to FIG. 5, an advantage of the structural element 10 is shown by cross braces 54, these are formed when diagonal force lines 50 cross. Cone force lines 56 provide a more probable representation of the route of forces through the structural element, although still result in cross braces 54 from the resultant force transferral. The result of these cross braces 54 is the transferral of the forces in multiple directions between the upper apex 64 and lower apex 66 of the diamond beams 30 and throughout the structural element 30 creating a matrix of compressive and tensile forces within the element when a load acts upon it. This structure thus offers the significant strength characteristics of a space frame, but without the complexity of joining multiple frame members or struts together to form that space frame.

[0137] A comparison to a space frame has been described here. However, whereas a space frame has a relatively straightforward predictability in terms of calculating its strength properties, with the structural element of the present invention the transferral of forces can be much more complex, especially where additional beams, ridges or surfaces are used in the structure of the pods or sheet materials This is since the structural element comprises load bearing surfaces between the struts, such as the planes and cones as opposed to just beams and struts. However, for the purposes of demonstrating the generic structural advantage of the present invention, particularly when compared to other structural elements which may use cross bracing or sheet materials in their structure, the comparison to space frames is of use and relevance.

[0138] The structural element 10 can be formed from a pair of sheets of material in a pressing machine. The machine punches the material for forming the cones 16. This might be a single sheet that is then folded to form the two sheets in opposition to each other, or more usuallyfor reducing machinery costit is two separate sheets. As such a first sheet is so formed and another sheet is likewise punched with its cones 16, this time extending toward the original sheet, and the two sheets and opposing cones are then joined at the truncated edge 20 of the cones 16.

[0139] The two sheets can be concurrently pressed and then joined in a later process, or such that two continuous sheets are fed into a single pressing and crimping or welding machine to be made in one pass. Either way, the manufacturing of the structural element may be part of a high speed manufacturing line, e.g. taking the sheet(s) off one or more roll of sheet material.

[0140] Although pressing machines are referred to, any appropriate material manipulation methods may be employed. These may include but are not limited to stamping, moulding and high temperature cutting and the chosen process may depend on the material used to form the structural element. Various metals are suitable for the structural element material, and many of them have many of the above processes as being applicable for their processing. Steel is a preferred material, as is aluminium. Preferably steel can be coated with a corrosion-resistant finishing material that is applied to or impregnated into its surfaces. This adds to the longevity and reusability of the structural element.

[0141] An advantage of metals is that a number of them have very wide operating temperature ranges, typically including safe upper temperature limits at or above the range of 100 c to 400 c. They can also be sterilised/autoclaved, and are non-flammable and hygienic, especially stainless steel.

[0142] The material to use is not limited to metal, as other materials may be used instead, these include plastics, paper or fibre based materials, graphene, composites, alloys, glass or glass fibre, ceramics, carbon fibre, plywood and laminated wood, chip board and plastic wood composites. The skilled person will also be aware of other appropriate material, depending upon the mode of manufacture to be used, be it forming or fabrication or moulding.

[0143] The material between the faces of the truncated edges 20 of the cones can be removed before or after joining the cones together, leaving a central circular hole 24. The removal of the material can thus be part of the first pressing process to increase efficiency, or it can be done later. It is not an essential step, and as such it can even be omitted if low weight is less critical. Nevertheless, the removal of the material will reduce the weight of the structural element 10 where this is a concern. In addition there may be advantages for having holes within the structural element for purposes such as ventilation. The removed material can also be recycled. However, if the material forming the faces of the truncated edges 20 remains, it can add addition strength to the structural element providing an additional surface for forces to be transmitted through, especially edge forces or skew forces.

[0144] The edges 26 of the structural element may be formed by bending of the sheet at each edge toward the opposing sheet and sealing or joining. The sealing or joining used at the edge, along with the joining of the truncated edges 20 of the cones 16 can use a number of material joining techniques such as crimping, riveting, welding, brazing, moulding, stapling, gluing, etc. The joining technique used can depend on the material used and the level of seal required. Materials can even be folded over one another in a loose-crimp or otherwise slotted or mechanically zipped together to form the structural element.

[0145] When forming the structural element from sheets, the thickness of the resulting structural element may be varied to alter the strength of the structural element. FIG. 8A shows a cross section of a sheet material 70 with a total thickness 72. This is a single thick sheet. This arrangement has a given strength. In FIG. 8B it can be seen that the sheet material 70 is cut in half to provide two half thickness sheetsi.e. the same amount of material, but from these two sheets it is possible to form the planes of the structural element 10, and also the pods or cones 16. The thickness 72 of the overall structure can thus be increased to increase the overall vertical load carrying strength of the structural element 10.

[0146] Referring then to FIG. 8C, the cones are stretched furtherthrough larger circular holes 18. This can further increase the strength, although there will be limits to how far the material of the sheets can be usefully stretched. As such, there is typically a preferred maximum cone-angle of 75 from the plane, although angles between 45 and 80 would be likely to be used.

[0147] Increasing the thickness 72 of each sheet can provide thicker walls for the cones 16 too. This can be used to allow the distance between the two sheets (the plane distance 74) to be increased further, since there is more material which can be stretched to form the cones 16.

[0148] The variation in cone size or depth can allow the structural element to be altered for various situations where dimensions or strengths are required. For example, where a sheet material 70 with a thickness 72 of 0.2 mm to 0.4 mm is used, the stiffness of the structural element 10 can be enhanced by increasing the plane distance 74 from 25 mm to 30 mm, or by reducing the diameter of the circular hole 18 (the directrix 76) from 50 mm to 40 mm. See FIG. 8D. Having the beams closer together or deepening them makes them typically more resistant to bending.

[0149] Other ways to change the strength of the structural element 10 may include varying the distance apart of the cones along the plane of the structural element, such that the diamond beam 30 has a more or less truncated apex. The cone 16, which has been described so far as a circular cone, can alternatively be changed to a different array of shapes. For example, see FIGS. 9A to 9H, which show various arrangements for the holes in the plane, and therefore various punched shapes for forming the pods in the sheet material. The first circular embodiment is shown in FIG. 9A, where circular holes 18 are arranged in offset rows. Other examples include various sized holes, triangular holes, square holes, hexagonal holes, elliptical holes, a combination of different shaped holes or indeed any number of polygons in any arrangement.

[0150] Where the holes are formed out of the sheet, the shape of the hole may have limits in terms of the degree of stretch available from the original sheet material.

[0151] The shape of the hole will help to determine what shape pod will be formed. For instance, as previously described, the circular holes 18 of FIG. 9A or FIG. 9B will typically form regular cone shaped pods.

[0152] There may be a need to add webbing or corrugations between adjacent pods to some formed shapes to increase the strength of the pod.

[0153] FIGS. 10 and 11 show an alternative embodiment of the structural element 80 according to the present invention. In this alternative structural element 80, the pods are similar to that as shown in FIG. 9C. Here the pods are square pods 82 and they are arranged in parallel rows and columns. Such an arrangement results in the diamond beam 30 being of a generally uniform sectional shape along the edge of each individual square pod 82. This arrangement results in the forces being more similar to that of a space frame, since between the intersections, the diamond beams are uniform for the transmittal of forces.

[0154] In this embodiment, webbing 84 has been formed at the corners of the square pods 82, this is helpful to increase the resilience of the structural element 80 to the twisting forces 86 which it may be subjected to. It also allows a deeper form for the pods since less stretching becomes necessary at the corners of the pods. FIG. 11 illustrates this webbing. It can be formed as the pod is formed (the cut-back flanges are only cut back for illustrative purposes)or it can be fitted after the pods are formed as a post-form attachment. The former is preferred due to the reduced component count and improved ease of manufacture.

[0155] FIG. 10 also shows within the grid of pods an area with a larger pod. This larger pod occupies the space of four normal pods (although it can be smaller or larger if preferred). By occupying a space equivalent to a whole number of normal pods, it can readily be formed without altering the structure of the surrounding pods.

[0156] The larger pod is for forming or receiving a leg of the structural element, thus allowing the integral formation of legs at the underside of the structural element, e.g. to offer the structural element in the form of a pallet. The legs can support the rest of the structural element above the ground.

[0157] To form the leg, the upper sheet is deformed with a large pod, whereas the lower sheet is deformed in an opposite direction to its normal with the deformed upper larger pod still engaging a part of the pod underneath it (the oppositely extending pod of the lower sheet). These two pods thus then form a strong leg for the pallet. For or more of these might be provided in a structural element if it is to be a palleteach being at or near corners of the structural element.

[0158] FIG. 12 shows an alternative design of pallet 100 which is formed from a panel 119 utilising the pod structure of the present inventionsimilar to the structural element 10 as seen in FIG. 1. The pallet comprises a panel 110 which is an enclosed structural element with panel edges 124. The panel 110 can accept objects or loads on its upper face 112, which is in this example the upper plane 12 of the structural element 10. In the panel 110 are the cones 16 which pass through a half thickness of the panel 110 to mate against corresponding cones extending upwards from the lower plane.

[0159] Pallets of this type can be used for the transportation of objects, since it allows easy movement with a fork lift truck due to the elevated platform and space underneath for forks thereof. They are also typically provided as a uniform or standardised dimension product, such that load location requirements can be predetermined. This also makes them very useful in stores and warehouses and transport vehicles, where shelves/load-bays can be designed to fit or receive a pallet.

[0160] Raising the panel 110 off the ground are legs 120. These legs 120 are shaped differently to the full cup shape of FIG. 10, and instead are half-cup shapessimilar to a cup which has been sectioned in half vertically, revealing open edges.

[0161] The legs 120 are aligned to the load-bearing surface of the pallet (the structural element part, or the panel) such that the top of the cup shape is flush with the upper face 112 of the panel 110 and the open edges of the cup are flush with the lower panel edge 124. This means that the legs 120 sit inside the periphery of the panel 110. The sides of the pallet thus have recesses in themat the legs.

[0162] Forming the base of the legs 120 is the bottom of the cup which has a generally semi-circular shape in plan. It also bends upwards to be a concave base when viewed from below, it thus extending upwards slightly inside the cup of the leg 120. This reduces the load area on the ground and also cooperates with a detail in the upper surface of a second identical pallet, as explained below.

[0163] There are four such legs in this example, although more legs can be provided if desired.

[0164] The tops of the legs 120 are wider than the bases of the legs 120. As such the sides of the legs are tapered. The legs 120 as shown also do not intersect any of the cones 16, but instead, where the leg 120 would interfere with the cones 16, the cones 16 have been omitted from the panel 110.

[0165] The profile of the leg 120 which extends through the panel in this example is generally curved, much like a semi-circle, as with the bottom of the cup, but here it is optionally more pronounced to approximate a three sided polygon with rounded edges. However any shape may be used when forming the cup shaped legs 120for the top or bottom of the leg, and in-between, although a smooth taper from top to bottom is preferred.

[0166] FIG. 13 shows two pallets 100 which are stacked on top of one another. The pallets 100 are arranged such that the legs 120 are aligned when viewed from a plan view. Since the legs 120 are shaped as half cups with no top, and the sides of the legs 120 are angled such that they are tapered toward the base, with the preferred smooth taper, the legs 120 of a lower pallet 100 allow the adjacent legs 120 of a pallet 100 above it to partially sit inside it. This allows the pallets to nest when stacked, and each additional pallet 100 added to the stack will nest in the pallet below it.

[0167] Nesting allows pallets to be stacked, particularly when they are not in use, and occupy less space vertically than two un-nested pallets. This can be useful for the transportation of the pallets, or for their storage, allowing more pallets to be placed in a single space.

[0168] The nesting also reduces horizontal movement or sliding of stacked pallets relative to one another since they are horizontally constrained between each other.

[0169] The degree of nesting can be determined by the shape of the legs. Changing the shape or adding a ridge thereon can stop one leg from slotting further inside another.

[0170] The legs can be shaped such that a panel 110 of a pallet 100 sits directly on top of a panel 110 of the pallet below it. This can be of some use when needing to reduce space occupied by stacked pallets and it will also allow for the transfer of forces between structural element panels 110if a greater load bearing capacity of panel was required. More common, however, is a requirement to maintain a larger gap between two stacked panels, perhaps to ensure that forks are able to fit between nested panels, or otherwise to allow their simple separation. After all, it is likely to be useful if pallets do not become difficult to un-nest from one another.

[0171] FIG. 14A shows in more detail an arrangement for a leg 120 and the nesting of an adjacent leg 122 which sits within the tapered inside surface of the leg 120. In this arrangement, the adjacent leg 122 in nested fully such that the panels 110 are in contact. It is also shown that the top of the leg 120 can sit within a larger fitting panel 124 than the top profile of the leg in FIG. 13three pods wide, not two.

[0172] The leg 120 may be separately moulded and then joined to the overall frame 110 by welding, brazing or other known techniques. Alternatively it can be of a design that can be pressed out of the sheets, as with FIG. 10. An arrangement where it is positioned in the corner of a pallet is shown in FIG. 14B. As can be seen there are four such legs, each in a sidewall/corner of the pallet. The pallet has square pods in its top panel rather than round ones. Additionally, the bottoms of the legs can connect with skids.

[0173] The forces which are exerted on the leg 120 can be transferred to the structural element of the panel through nodes 126, which are the apices of diamond beams within the panel 110. Therefore there is an efficient transfer of forces through the legs 120 into the structural element.

[0174] The legs 120 of the pallet 100 shown in FIGS. 12 and 13 do not all sit at the four outermost corners of the panel 110, but instead two of the legs are inset from this edge, resulting rusting in an overhang 130 on one edge of the pallet, and the others are at an end, but located on a side, rather than symmetrically at the corner. Other positions are possible. However, FIG. 15 shows that due to the overhang 130 and inset legs, when two pallets 100 are stacked with the overhang 130 at opposite edges, if the panel edges 124 of the two pallets are kept vertically in-line from a plan view, the pallets 100 may stack without full nesting. Further pallets can be stacked in this manner, and since the overhang 130 alternates sides, this mode of stacking maintains a straight stack since the centre of gravity is not eccentric over lower stacked pallets.

[0175] Such stacking without nesting may be useful when objects shorter than the legs are loaded onto the pallets, or when a small number of the pallets are to be stored or movedthe gaps between the panels readily receive forks of a forklift.

[0176] An additional feature of the pallet 100 that is useful when stacking pallets without full nesting, is the groovehere a semi-circular circular groove 132present adjacent to the top of the legs on the upper face 112 of the pallet 100. There are four of themone by each leg top. The circular groove 132, in each case, is an indentation in the top sheet shaped such that the base of the legs 120 (with its concave detail) can locate within the circular groove. This allows, when stacking, a guide to ensure the legs 120 are located in the ideal location to ensure the maximum stability for the stacked pallet structure. Further, since the pallet may be formed of a rigid material with a smooth surface (e.g. a metal), there may be an increased tendency for pallets to slide when stacked or nudged. The circular grooves 132 have the added feature of reducing sideways movement of the pallet 100 since they add an additional vertical movement necessary for any sideways movement, and since they are not linear, they encapsulate the leg bases.

[0177] Although a circular groove is shown, any shape which relates to the base of the leg of the pallet may be used. In particular, other shapes are possible which will provide stability.

[0178] The encapsulation function is also beneficiali.e. for the prevention of slippage through some or all grooves simultaneously. This may be achieved with blind slots, angular slots, or differently orientated grooves at the respective leg positions around the surface of the pallet. In the present example, this already occurs since the semi-circles face opposite direction on opposite sides of the pallet.

[0179] Alternatively a rough surface may be applied at the points of contact to reduce the tendency for horizontal relative movement.

[0180] The present invention can also comprise such a pallet fitted with separate skids. Many conventional pallets have skids to form the bases. For example, see the arrangement as shown in FIG. 16. This skid plate 136 extends between two legs 120 and has a groove similar to that of the circular groove 132 for locating the leg 120 onto the skid plate 136. The leg 120 may then be attached to the skid plate 136 by joining methods such as welding. Other leg base and groove designs are naturally possible, as discussed above for the grooves in the upper surface of the plate.

[0181] The skid plate 136 allows the pallet 100 to be used in situations where legs 120 may cause a point load and damage the surface on which they are stood, or where legs 120 would be impractical, for instance on a conveyer belt of a factory where pallets may have goods loaded directly onto them. The use of a skid plate 126 also allows the pallets 100 to be manufactured with just legs 120 and the skid plates 136 added afterwards, thus removing the need for two pallet manufacturing processes. The skid plates 136 can also be of a different material to the pallet 100, or have a softer material bonded to their underside, this may be useful where a harder material of a pallet may damage a surface, but a soft base, such as wood, can reduce the likelihood of scratches on floors due to pallets being slid about.

[0182] The skid plate 136 would mean that nesting of the pallet was no longer possible, however, FIG. 17 shows an alternative arrangement for nesting pallets which could apply when a skid plate 136 is installed. Here, due to the overlap 132, a pallet 100 can be inverted relative to another pallet so that the legs 120 sit next to the adjacent legs 122 of the other pallet. This can provide the same reduction in height when nesting two pallets as the legs 120 without the skid plates 136. In addition grooves can be present on the underside of the panel 110 for locating the legs 120 or skid plates 136 when inverted nesting the pallets. This mode of nesting can likewise be used without the skid plates.

[0183] The present invention may even reside in the design of a skid plate 136, See FIGS. 22 to 24. After all, the elongate skid member may be formed as a structural element using the pods structure, it thus being a structural element according to the present invention. As shown in FIG. 22, the skid can be formed with more than one section of structural element, here attached to one another along a foldable lower sheet member. The sides are angled and through folding and welding of the structural members together, the U shaped skid can be formed. This can then be attached to a pallet top, such as one that is in accordance with the present invention as shown in FIG. 23.

[0184] FIG. 23 shows two skids on the pallet, one being recessed from an end to leave an overhang, as previously discussed. FIG. 24 instead shows three skidstwo end skids and a middle skid. Other arrangements are also within the scope of the invention. FIG. 24 also shows the pods in a non-staggered, grid-like array. This is another option for the circular holes 18.

[0185] Due to the advantages afforded by the legs 120 with and without the skid plates 136, it may be desirable to have a pallet which has the benefit of both. FIG. 18 shows a base plate 140. This base plate either has skid plates 136 mounted to it, so a pallet can be put onto the skid plates, or it receives a pallet with such skid plates on it. It may even be provided without skid plates between the pallet and the base platethe base plate thus then having, preferably, the above-described groove feature for directly receiving a pallet with legs. This allows the pallet 100 to be placed on the base plate 140 and the base of the feet 120 be secured thereon by the grooves in the skid plates or in the base plate 136.

[0186] The base plate 140 may be used on production lines with conveyer belts and allow the pallets to move along without risk of the legs 120 lacking the surface area to be sufficiently carried by the conveyer belt.

[0187] The pallets can be manufactured from two sheets of material which are punched to form the necessary shape and removing the space for the legs 120. This can be one pressing motion with a continuous sheet of material being passed through the machine and cut up later into panel 110 sized blocks. The pressed sheet is then joined to an opposing pressed sheet at the cone bases.

[0188] The legs 120 can even be extruded from the sheets of material, although if thicker material is required to provide strength, or if a greater form height than that which would be safely achievable from the sheets is required, then a separate joining method will be preferable for the legs.

[0189] Many materials can be used for forming the pallets 100, although metal sheet materials particularly suit the process. Metals also have the added benefit of being easily cleaned and sterilized. This can be important when transporting goods on pallets to countries where there are strict laws about imports, such as those where wooden pallets would be prohibited due the possibility of carrying insects or foreign matter, or in general for food stuffs. Stainless steel, aluminium and plastics may be useful materials in that respect due to their sterilisability, and thus reusability. However, many other materials are also reusable or recyclableof benefit in other sectors.

[0190] The weight of a pallet can also be important, and the sheet material offers the ability to produce a pallet of great strength with minimal weight. The cones 16, with the centres removed also reduce the weight of the pallet. For example, whereas a conventional wooden pallet may weigh about 10 kg (for a typical 600800 pallet), an equivalent pallet of the present invention, made of 0.24 mm steel, taken off coils of sheet steel and pressed to the required shape with the pods as shown in FIG. 12, which pallet will offer a similar safe working load capacity to that of the prior art timber one, may weigh only 1.8 kg.

[0191] It is preferred that for a 1200800 pallet, the weight of the pallet, when utilising the present invention, does not exceed 4.0 kg.

[0192] The thickness of the sheets of steel preferably do not exceed 1 mm, but more typically will not need to exceed 0.4 mm or even 0.3 mm. 0.24 mm has been found to be adequate for standard pallet sizes.

[0193] In terms of the thickness of the panels, where the sheets are made of mild steel, a sheet having a thickness of 0.25 mm can theoretically be stretched safely to provide a panel having a depth of about 40 mm. It is preferred that the pods from such sheet material do not exceed a depth of 25 mm. In general this equates to a preferred pod height not exceeding 10x the thickness of the sheet material.

[0194] The cones 16 in the pallet 100 also have a number of other features. They allow the circulation of air around the object on the pallet, this can be important when consignments must be heated or cooled to certain temperatures before travelling. This is commonly useful in the logistics industry, especially in the cold chain where the speed of bringing consignments down to the desired temperature affects operating costs and consignment quality. With the pods of the present invention's structural element, this airflow is achieved substantially evenly across the entire panel, especially with square or other high-packing-density pod shapes such as triangles and hexagons. The cones 16 also ensure that if liquids fall onto the pallet, or they are left outside in the rain, no liquid can gather in pockets in the pallet. This can also apply to dirt, where it will be washed through the holes of the pallet, and, if necessary, can easily be cleaned by spraying water.

[0195] The cones 16 also provide an uneven surface which softer objects carried on the pallet may sink into and thus be more secure on the pallet.

[0196] It is preferred that in any design that the apex of the beams/borders of the top-surface holes 18 have a rounded edge so that it is smooth to prevent cutting, tearing or other sharps damage to goods stored or located on the pallets.

[0197] Although a specific use in pallets has been discussed, the structural element may be used in any number of further applications. FIGS. 19 to 21 gives some further examples of the use of the structural element, although the use is not limited to these.

[0198] FIG. 19 shows a box, which may be formed of cardboard or any other suitable material which has the internal structure of the structural element. This will provide additional strength to the box and may allow additional stacking of boxes, which may make transport easier and result in fewer goods damaged in delivery due to boxes being crushed.

[0199] Corrugated sheets in general can likewise benefit from the present invention's structure, e.g. using a touch adhesive on the internal faces of the two pod-formed sheets.

[0200] The structural element can includes a means of counterfeit protection. When considering card, a specific paper grade or an injected chemical signature in the pulp can be utilized. A particular or distinctive image or pattern, etc. can be printed on the inner, unseen, surfaces of the sheets to further provide some counterfeit protection.

[0201] Such techniques can provide a subtle, or difficult to reproduce signature which can be used to identify the structural element.

[0202] FIG. 20 is a skateboard where the structural element is used to form the board or platform, this uses the advantages of the structural element of the present invention to create a lightweight yet strong platform, which can reduce the weight of the skateboard.

[0203] FIG. 21 is a lorry where the trailer is formed from panels of the structural element according to the present invention. This can provide a strong side of a lorry trailer, protecting the loads inside and also, due to the shape of the cones on the surface of the panels, may reduce pressure drag past the sidewalls of the vehicle as the vehicle moves along the road. This is achieved since the pods can creating a turbulent flow on the panel's surface, thus and reducing the wake of pressure difference. This is similar to the dimples of a golf ball. For this it is preferred that the cones or pods are generally rounded, or relatively shallow, i.e. not exceeding 25% of their maximum outer diameter or maximum outer linear dimension,

[0204] The present invention has therefore been described above by way of example. It provides a structural element (10) with an upper plane (12) and lower plane (14) which are parallel and deformed along their plane at intervals by pods (16) which extrude toward the opposing plane with their internal faces mating to one another.