STACKABLE PALLET
20260091910 ยท 2026-04-02
Assignee
Inventors
Cpc classification
B65D2519/00363
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00273
PERFORMING OPERATIONS; TRANSPORTING
B65D19/004
PERFORMING OPERATIONS; TRANSPORTING
B65D2519/00338
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A pallet assembly includes a top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck. At least one vertical support is connected to the top deck and extends perpendicularly from a central axis below the top deck and includes stabilizing feet which extend longitudinally along a width direction of the top deck. A second interlock pattern is disposed on all or a portion of the at least one vertical support or the stabilizing feet. One of the first interlock pattern and the second interlock pattern includes one or more protrusions, while the other of the first interlock pattern and the second interlock pattern includes apertures or channels for receiving the one or more protrusions.
Claims
1. A pallet assembly, comprising: a top deck, the top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck; at least one vertical support connected to the top deck and extending perpendicularly from a central axis below the top deck, the at least one vertical support comprising stabilizing feet which extend longitudinally along a width direction of the top deck; and a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet; wherein one of the first interlock pattern and the second interlock pattern comprises one or more protrusions and the other of the first interlock pattern and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions.
2. The pallet assembly of claim 1, wherein the top deck and the at least one vertical support are releasably joined.
3. The pallet assembly of claim 1, wherein the first interlock pattern comprises one or more protrusions and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions.
4. The pallet assembly of claim 1, wherein the second interlock pattern comprises one or more protrusions and the first interlock pattern comprises one or more apertures or channels for receiving the one or more protrusions.
5. The pallet assembly of claim 1, further comprising a plurality of vertical supports, each having a respective set of stabilizing feet.
6. The pallet assembly of claim 1, further comprising a vertical support lacking stabilizing feet.
7. The pallet assembly of claim 1, wherein the stabilizing feet extend longitudinally for a distance that is less than a width of the top deck.
8. The pallet assembly of claim 1, wherein the stabilizing feet extend longitudinally for a distance that is equal to or greater than a width of the top deck.
9. The pallet assembly of claim 1, wherein the stabilizing feet further comprise an outer sleeve and an inner sleeve which telescopically adjust for a distance that is less than, equal to, or greater than a width of the top deck.
10. The pallet assembly of claim 1, wherein the two or more of the at least one vertical supports are connected by one or more cross braces.
11. The pallet assembly of claim 10, wherein the one or more cross braces comprise an interlock pattern disposed on at least a portion of a cross brace surface.
12. The pallet assembly of claim 1, wherein the top deck further comprises apertures which are configured to receive a fork on a forklift or pallet jack.
13. The pallet assembly of claim 1, wherein the top deck and the at least one vertical support comprise the same material.
14. The pallet assembly of claim 1, wherein the at least one vertical support and the stabilizing feet comprise the same material.
15. The pallet assembly of claim 13, wherein the material comprises a plastic selected from the group consisting of high-density polyethylene (HDPE), polypropylene, acrylonitrile butadiene styrene, polycarbonate, and a combination thereof.
16. The pallet assembly of claim 1, wherein the top deck and stabilizing feet are configured to be aligned by one or more tongue-and-groove connections within the apertures or channels.
17. A stacked pallet system comprising: a first pallet assembly and a second pallet assembly, each of the first pallet assembly and the second pallet assembly comprising: a top deck having a first interlock pattern; at least one vertical support attached to a bottom surface of the top deck and extending perpendicular from a central axis of the top deck, the at least one vertical support comprising stabilizing feet; and a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet; wherein one of the first interlock pattern and the second interlock pattern comprises one or more protrusions and the other of the first interlock pattern and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions; and wherein the second pallet assembly is stacked on top of the first pallet assembly such that the first interlock pattern of the first pallet assembly mates with the second interlock pattern of the second pallet assembly.
18. A method of arranging stackable pallets comprising: providing a plurality of pallet assemblies, the pallet assemblies each comprising a top deck having a first interlock pattern, at least one vertical support attached to a bottom surface of the top deck and extending perpendicular from a central axis of the top deck, the at least one vertical support comprising stabilizing feet; and, a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet; wherein the first interlock pattern and the second interlock pattern are complementary; and mating the second interlock pattern of the vertical support and/or stabilizing feet of a first pallet assembly with the first interlock pattern of the top deck of a second pallet assembly.
19. A pallet assembly, comprising: a top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck; at least one vertical support extending perpendicularly from a central axis below the top deck and, the at least one vertical support comprising stabilizing feet which extend longitudinally along a width direction of the top deck; and a second interlock pattern disposed on at least a portion of the at least one vertical support; wherein one of the first interlock pattern and the second interlock pattern comprise one or more protrusions and the other of the first interlock pattern and the second interlock pattern is configured to receive the one or more protrusions.
20. The pallet assembly of claim 19, wherein the first interlock pattern comprises a continuous protrusion following a perimeter of the top deck.
21. The pallet assembly of claim 1, wherein the assembly is configured to be transported using a conventional walk behind electric forklift.
22. The pallet assembly of claim 1, wherein the assembly has a size of a conventional half pallet.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Other features and advantages of the processes and compositions disclosed herein will be apparent to those skilled in the art reading the following detailed description in conjugation with the exemplary embodiments illustrated in the drawings, wherein:
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
DETAILED DESCRIPTION OF THE INVENTION
[0030] Pallets are generally flat structures designed for the transportation and support of goods. Pallets can be made from a variety of materials, with common examples being wood, plastic, and metal pallets. Each of these types of pallets has advantages and disadvantages, which warehouse and shipping operators must consider when selecting appropriate pallets for specific use cases.
[0031] Pallets may additionally be designed for transportation of goods in a secure fashion while being lifted by a forklift, a pallet jack, a front loader, a jacking device, or a crane.
[0032] Although pallets come in all sizes and configurations, pallets may fall into certain categories including stringer and block pallets. Block pallets utilize both parallel and perpendicular stringers to better facilitate efficient handling. A block pallet is also known as a four-way pallet, since a pallet-jack may be used from any side to move it. Stringer pallets are one of the original models of wooden pallets. They use a frame of three or more parallel pieces of timber (called stringers). The top deckboards are then affixed to the stringers to create the pallet structure. Stringer pallets can have a notch cut into them allowing four-way entry. Forklifts can lift a stringer pallet from all four directions, though lifting by the stringers is more secure. Stringer pallets can be made of both wood and plastic.
[0033] Plastic pallets are beneficial as they can be made from new or recycled materials, are durable, resist weathering, rot, chemicals, odors, and corrosion and can be sanitized easily. Some plastic pallets additionally have fire retardancy. Plastic pallets are also lighter weight than wooden pallets, saving on transportation and labor costs and making them safer and more environmentally friendly.
[0034] Plastic pallets are often stackable. The ability to stack loaded or empty pallets allows for easy storage and transportation when not in use.
[0035] Plastic pallets can be made by high pressure injection molding, structural foam molding, thermoforming, compression molding, rotational molding, or profile extrusion.
[0036] For economical pallet use, it is desirable to have a stable pallet with the ability to pass through standard doors and buildings. Smaller size pallets are beneficial for Direct Store Delivery methods, where, in place of delivery of an entire pallet of goods, retailers may load the desired product onto half pallets and display them directly in the retail space as a small footprint store model. However, pallets narrow enough to achieve these dimensions have stability concerns. One resolution has been to provide pallets with feet that stick out laterally to provide increased stability, while allowing forklift access from underneath. This configuration, too, provides occupational hazards such as tripping or catching during transportation.
[0037] There is therefore a need to create a stackable pallet system which can fit through standard building construction and which avoids tripping or catching hazards while providing stability such as not to tip over during use.
[0038] The following provides a description of various exemplary embodiments of the disclosure, as used in the context of a stackable pallet and method of stacking the same. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles and features of various aspects of the present invention. The scope of the present invention is not limited by this description.
[0039] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which this invention belongs. Specific methods, devices, and materials are described, although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.
[0040]
[0041] The pallet assembly 100 includes three components: a top deck 110, one or more vertical supports 120, and one or more stabilizing feet 130. Top deck 110 has a load bearing surface 111 which may be solid or perforated (e.g., configured as a lattice). Load bearing surface 111 is configured generally to allow for receiving, storing, and transport of goods atop pallet assembly 100 while in use.
[0042] Top deck 110 may include a first interlock pattern 112 disposed on at least a portion of top deck 110. The first interlock pattern 112 may be disposed upon load bearing surface 111. First interlock pattern 112 may include one or more protrusions which fit complimentarily to or mate with a second interlock pattern 135. Second interlock pattern 135 may comprise apertures or channels configured to accept the protrusions from first interlock pattern 112 to allow top deck 110 to nest in the protrusions of second interlock pattern 135. Second interlock pattern 135 may be located on the vertical supports 120, stabilizing feet 130, cross brace 140, or a combination of the same. Alternatively, first interlock pattern 112 may comprise one or more apertures or channels which are configured to accept protrusions from second interlock pattern 135, allowing top deck 110 and stabilizing feet 130 or vertical supports 120 to nest together in a rigid manner. The combination of first and second interlock pattern 112, 135 enhances the stability of the stacking structure and reduces the possibility of damage during transportation and storage due to dislodgment.
[0043] The one or more apertures or channels may be any patterned and/or recessed surface (e.g., a groove) which can accept part or all of a protrusion. The apertures or channels may be rounded, squared, or feature other shapes which would allow for a complementary fit by the protrusion and reduce or prevent lateral movement between first interlock pattern 112 and second interlock pattern 135. Similarly, the protrusions may be any shape which is complementary to or capable or mating with said aperture or channel.
[0044] In one embodiment, first interlock pattern 112 may comprise a protrusion which does not extend beyond the cumulative height of load bearing surface 111. In other words, the absence of material within load bearing surface 111 on top deck 110 may cause said protrusions which are configured to fit complementarily in the apertures or channels of second interlock pattern 135. The same may be said with second interlock pattern 135 of vertical supports 120, stabilizing feet 130, or cross brace 140, where the protrusions may be created by a lack of material such that the protrusions do not extend beyond the overall thickness of the vertical support 120, stabilizing feet 130 or cross brace 140. The apertures and protrusions may be sized, oriented, and shaped in a manner which allows for additional support to be provided on load bearing surface 111 to prevent sagging of top deck 110 by the weight of product on the surface. For example, the apertures and protrusions may be oriented such that there is a greater ratio of apertures to protrusions to use less material during construction and/or create a lightweight product while maintaining structural integrity of the top deck 110 to prevent sagging of the same. Alternatively, the apertures and protrusions may be oriented such that the apertures are smaller in size and/or spaced to allow for greater contact of material on load bearing surface 111, where such orientation allows for more contact area between load bearing surface 111 and the product to prevent sagging of the product placed on top deck 110.
[0045] The at least one vertical support 120 may extend perpendicularly from a central axis below top deck 110. The at least one vertical support 120 may additionally include stabilizing feet 130 which extend about a horizontal axis, or longitudinally along a width direction of top deck 110, from vertical support 120. The at least one vertical support 120 and/or stabilizing feet 130 may have a second interlock pattern 135 disposed on all of a portion of at least one vertical support 120 or stabilizing feet 130. Second interlock pattern 135 may comprise apertures or channels which are configured to accept protrusions from first interlock pattern 112 or may comprise protrusions which are configured to insert into first interlock pattern 112. It typically follows that stabilizing feet 130 and at least one vertical support 120 have the same or corresponding second interlock pattern 135 disposed on them so as to be complementary to first interlock pattern 112 that is chosen for the particular pallet assembly 100.
[0046] As may be seen in
[0047]
[0048] Top deck 110 of pallet assembly 100 and at least one vertical support 120 may be releasably joined. The releasable joint may occur via any lock mechanism, such as releasable joints, latch and lock, tongue-and-groove, releasable fit, snap joint, or other methods for releasable attachment which may be contemplated.
[0049] Pallet assembly 100 may have one or more vertical supports. As may be seen more specifically in
[0050]
[0051] As seen in
[0052] Stabilizing feet 130 may be adjustable and may further consist of an outer sleeve and an inner sleeve which allow for telescoping of stabilizing feet 130 to adjust horizontally the width of less than, equal to, or greater than the top deck 110.
[0053] As depicted in at least
[0054]
[0055] As shown in
[0056]
[0057] As may be seen more specifically in
[0058]
[0059] Again, as above and seen in
[0060] Stabilizing feet 130 may be adjustable and may further include an outer sleeve and an inner sleeve which allow for telescoping of stabilizing feet 130 to adjust horizontally outwards towards the width of less than, equal to, or greater than the direction of top deck 110.
[0061]
[0062] As shown in
[0063] In another embodiment, first interlock pattern 112 additionally comprises a protrusion 160 following along the perimeter of load bearing surface 111 of top deck 110. The protrusion 160 may be continuous and may extend upwards vertically along a central axis of top deck 110. The protrusion 160 does not interfere with second interlock pattern 135. The protrusion 160 follows an outline of top deck 110 to prevent possible lateral movement of a second pallet assembly beyond the perimeter of the first pallet assembly. In one example, a continuous protrusion 160 forms a rectangle complementary to the shape of top deck 110. In another example, the protrusion 160 of a first pallet assembly 100 is not continuous but is contiguous with a complementary recessed portion of a second pallet assembly 100, allowing load bearing surface 111 to be planar to fully support any product placed atop.
[0064] The components of pallet assembly 100, 300 may be made from plastic, though other materials are contemplated. Pallet assembly 100, 300 may be made of plastics such as high-density polyethylene (HDPE), polypropylene, acrylonitrile butadiene styrene, polycarbonate, or a combination of the same. In other non-limiting embodiments, the components of pallet assembly 100 may be metal, metal-reinforced wood, or other hybrid materials. It is contemplated in this disclosure that the separate parts of pallet assembly 100, 300 may not be made of the same type of plastic material. For example, it is possible that top deck 110 may be HDPE, while vertical supports 120 may be made of polypropylene.
[0065] The geometry of first interlock pattern 112 and second interlock pattern 135 may be elaborate. Thus, the profile of load bearing surface 111 or resting surface 150 may be interrupted at places by openings. The profile may also be affected by normal manufacturing variations, or by the addition of intentional minor variations in shape. Other alternatives and variations will be apparent to persons of ordinary skill in the art in view of the present disclosure.
[0066] The pallet assembly 100, 300 may be the size of a conventional full pallet, half pallet, or a size therebetween. It is a beneficial aspect of a particular embodiment that the stacked pallet assemblies are stable to prevent tipping by uneven weight distribution.
[0067] Also contemplated herein is a method of stacking pallet assemblies 100, 300, where a plurality of pallet assemblies is provided to be stacked atop one another. The pallet assemblies again each have a top deck, at least one vertical support attached to a bottom surface of the top deck and extending downwards from a central axis of the top deck, at least one vertical support having stabilizing feet. The top deck has a first interlock pattern and the at least one vertical support and/or stabilizing feet have a second interlock pattern. This allows for one pallet assembly is placed atop another with the first interlock pattern in alignment with the second interlock pattern, which are complementary. The second interlock pattern of the vertical support and/or stabilizing feet of the first pallet assembly is nested with the first interlock pattern of the top deck of a second pallet assembly. This stacking of pallet assemblies may continue repeatedly.
[0068] The present disclosure relates to examples of embodiments of a pallet that is adapted to be stacked in a manner which minimizes the likelihood of tipping and allows for easy transportation. It will be appreciated that features of embodiments may be used without other features, or in different combinations, to beneficial effect. Furthermore, it will be appreciated that certain features of the embodiments may be selected for ornamental design and are not dictated by practical function. For example, the dimension of the pallet assembly, the shape of the apertures/channels, the shape of the protrusions, the pattern of load bearing surface 111 and resting surface 150, the number, density, and length of vertical supports 120, and other features may be selected based to some degree or entirely according to aesthetic preferences. Accordingly, design elements of these features can be varied and selected while maintaining functionality, such that a variety of ornamental configurations are available with substantially the same function or performance.
[0069] Unless otherwise stated, any and all measurements, values, ratings, positions, magnitudes, sizes, angles, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. Such amounts are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. For example, unless expressly stated otherwise, a parameter value or the like may vary by as much as +5% or as much as +10% from the stated amount. The terms substantially, generally, or fully means that the parameter value or the like varies up to +25% from the stated amount. The terms generally, or fully means that the parameter value may vary from an ideal value by 25%, i.e., a parameter may conform to its descriptors by as little as 75%.
[0070] The scope of protection is limited solely by the claims that now follow. That scope is intended and should be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirement of Sections 101, 102, or 103 of the Patent Act, nor should they be interpreted in such a way. Any unintended embracement of such subject matter is hereby disclaimed.
[0071] It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms comprises, comprising, includes, including, has, having, containing, contain, contains, with, formed of, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises or includes a list of elements or steps does not include only those elements or steps but may include other elements or steps not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by a or an does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
[0072] In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various examples for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed examples require more features than are expressly recited in each claim. Rather, as the following claims reflect, the subject matter to be protected lies in less than all features of any single disclosed example. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
[0073] While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present concepts.