PALLET WITH STRAP CHANNELS, STRAPPING MACHINE, AND METHODS OF STRAPPING A LOAD

Abstract

Various embodiments of the present disclosure provide a method of strapping a load, a strapping machine for strapping a load, and a pallet with strap channels.

Claims

1. A method of strapping a load, the method comprising: moving the load to a strapping area on a load supporter of a strapping machine, wherein the load comprises a pallet and goods supported by the pallet, wherein the pallet comprises a base and a top deck connected to the base and has opposing first and second ends and opposing first and second sides transverse to the first and second ends, wherein an underside of the base defines a first strap channel adjacent the first end of the pallet and a second strap channel adjacent the second end of the pallet, wherein the first and second strap channels extend from the first side to the second side; stopping the load in the strapping area so a strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via a strapping head of the strapping machine, strap from a strap supply through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the first strap channel; and tensioning, via the strapping head, the strap around the load.

2. The method of claim 1, wherein feeding the strap comprises: feeding, via the strapping head, the strap from the strap supply through the strap chute before the load stops at the strapping area.

3. The method of claim 1, further comprising: moving the load to a second strapping area on the load supporter of the strapping machine; stopping the load in the second strapping area so the strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via the strapping head, strap from the strap supply through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the second strap channel; and tensioning, via the strapping head, the strap around the load.

4. The method of claim 3, wherein the underside of the base defines a third strap channel positioned at a center of the pallet, the method comprising: moving the load to a third strapping area on the load supporter of the strapping machine; stopping the load in the third strapping area so the strap chute of the strapping machine circumscribes the load and so the third strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via the strapping head, strap from the strap supply through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the third strap channel; and tensioning, via the strapping head, the strap around the load.

5. The method of claim 1, further comprising: moving the load to a second strapping area on a load supporter of a second strapping machine; stopping the load in the second strapping area so a strap chute of the second strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via a strapping head of the second strapping machine, strap from a strap supply of the second strapping machine through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head of the second strapping machine, the strap from the strap chute and onto the load so part of the strap is received in the second strap channel; and tensioning, via the strapping head of the second strapping machine, the strap around the load.

6. The method of claim 5, wherein the underside of the base defines a third strap channel positioned at a center of the pallet, the method comprising: moving the load to a third strapping area on a load supporter of a third strapping machine; stopping the load in the third strapping area so a strap chute of the third strapping machine circumscribes the load and so the third strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via a strapping head of the third strapping machine, strap from a strap supply of the third strapping machine through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head of the third strapping machine, the strap from the strap chute and onto the load so part of the strap is received in the third strap channel; and tensioning, via the strapping head of the third strapping machine, the strap around the load.

7. The method of claim 1, wherein stopping the load in the strapping area comprises: stopping the load so a first strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the first strap chute extending across the load supporter and so a second strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the second strap chute extending across the load supporter.

8. The method of claim 1, wherein the underside of the base comprises an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, first and second side edges which are substantially parallel to one another, and wherein the first strap channel adjacent the first end of the pallet and the second strap channel adjacent the second end of the pallet extend from the first side to the second side.

9. A strapping machine for strapping a load, the strapping machine comprising: a load supporter configured to support the load, wherein the load includes a pallet and goods supported by the pallet, wherein the pallet comprises a base and a top deck connected to the base and has opposing first and second ends and opposing first and second sides transverse to the first and second ends, wherein an underside of the base defines a first strap channel adjacent the first end of the pallet and a second strap channel adjacent the second end of the pallet, wherein the first and second strap channels extend from the first side to the second side; a strapping head; a strap chute defining a strap path and configured to receive strap from a strap supply; and a controller, wherein the controller is operably connected to the strapping head and configured to: move the load to a strapping area on the load supporter; stop the load in the strapping area so the strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feed, via a strapping head of the strapping machine, strap from a strap supply through the strap chute along a strap path defined by the strap chute; retract, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the first strap channel; and tension, via the strapping head, the strap around the load.

10. The strapping machine of claim 9, wherein the controller is further configured to: move the load to a second strapping area on the load supporter; and stop the load in the second strapping area so the strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter.

11. The strapping machine of claim 9, wherein the strapping head comprises: a feed module configured to feed the strap; a tensioning module configured to tension the strap; and a sealing module configured to: hold a leading strap end of the strap; cut the strap from the strap supply to form a trailing strap end of the strap; and connect the leading strap end to the trailing strap end.

12. The strapping machine of claim 11, wherein the controller is further configured to: control the feed module to feed the strap from the strapping head through the strap chute along the strap path; control the tensioning module to tension the strap around the load; and control the sealing module to hold the leading strap end, form the trailing strap end, and connect the leading strap end to the trailing strap end to form a tensioned strap loop.

13. The strapping machine of claim 9, further comprising a second strap chute configured to receive strap from the strap supply.

14. The strapping machine of claim 13, wherein the controller is configured to: feed a first strap from the strap supply through the strap chute along a strap path defined by the strap chute; feed a second strap from the strap supply through the second strap chute along a second strap path defined by the second strap chute; and tension the first strap and the second strap around the load.

15. The strapping machine of claim 14, wherein the controller is further configured to: move the load to a strapping area on the load supporter; and stop the load in the strapping area so the strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter and so the second strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the second strap chute extending across the load supporter.

16. The strapping machine of claim 9, further comprising a plurality of strap chutes configured to receive strap from the strap supply.

17. The strapping machine of claim 9, wherein the strap chute comprises a first side and a second side such that the first side and the second side are hinged together at a hinge joint, and wherein the first side and the second side are configured to retain the strap supply until the first side and the second side are hinged apart at the hinge joint to release the strap supply.

18. A pallet for supporting goods, the pallet comprising: a top deck; a base, wherein the base comprises a bottom deck having an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, first and second side edges which are substantially parallel to one another, and wherein the bottom deck comprises: two or more front strap channels configured to receive strap, wherein the two or more front strap channels extend from the front edge to the back edge, wherein a first side strap channel of the two or more front strap channels is adjacent to the first side edge, and wherein a second side channel of the two or more front strap channels is adjacent to the second side edge; and two or more side strap channels configured to receive strap, wherein the two or more side strap channels extend from the first side edge to the second side edge, wherein a front strap channel of the two or more side strap channels is adjacent to the front edge, and wherein a back strap channel of the two or more side strap channels is adjacent to the back edge; and a plurality of spacers extending substantially perpendicularly downward from the top deck to the base, wherein the plurality of spacers separate the top deck and the base.

19. The pallet of claim 18, wherein the top deck includes a plurality of openings.

20. The pallet of claim 18, the pallet further comprising a plurality of fork inlets, wherein each fork inlet is configured to receive a fork of a forklift.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0012] FIG. 1A is a perspective view of one example embodiment of a pallet of the present disclosure having two strap channels.

[0013] FIG. 1B is an underside view of the pallet in FIG. 1A showing the two strap channels.

[0014] FIG. 2A is a perspective view of another example embodiment of a pallet of the present disclosure having three strap channels.

[0015] FIG. 2B is an underside view of the pallet in FIG. 2A showing the three strap channels.

[0016] FIG. 3A is a perspective view of one example embodiment of a strapping machine.

[0017] FIG. 3B is a perspective view of the strapping machine of FIG. 3A and a load approaching a strapping area on a load supporter of the strapping machine.

[0018] FIG. 3C is a perspective view of the strapping machine of FIG. 3A and the load of FIG. 3B in the strapping area with a first strap channel of the pallet aligned with a portion of a strap chute of the strapping machine.

[0019] FIG. 3D is a perspective view of the strapping machine of FIG. 3A and the load of FIG. 3B in the strapping area with a second strap channel of the pallet aligned with a portion of a strap chute of the strapping machine.

[0020] FIGS. 3E and 3F are cross section views of the strapping machine and the load in FIG. 3C.

[0021] FIG. 4 is a flowchart showing a method of strapping a load.

[0022] FIG. 5A is a plan view of another example embodiment of a strapping machine and a load approaching the strapping area.

[0023] FIG. 5B is a plan view of the strapping machine of FIG. 5A and the load of FIG. 5A in the strapping area with a first strap channel of the load aligned with a portion of a strap chute of the strapping machine.

[0024] FIG. 5C is a plan view of the strapping machine of FIG. 5A and the load of FIG. 5A in the strapping area with a second strap channel of the load aligned with a portion of a strap chute of the strapping machine.

[0025] FIG. 5D is a plan view of the strapping machine of FIG. 5A and the load of FIG. 5A strapped through the first strap channel and the second strap channel downstream of the strapping area of the strapping machine.

[0026] FIG. 6A is a perspective view of a load having a pallet with two strap channels having been strapped in two directions.

[0027] FIG. 6B is an underside view of the pallet in FIG. 6A showing the two strap channels on each side of the pallet with straps within them.

[0028] FIG. 7A is a perspective view of a load having a pallet with three strap channels having been strapped in two directions.

[0029] FIG. 7B is an underside view of the pallet in FIG. 7A showing the three strap channels on each side of the pallet with straps within them.

DETAILED DESCRIPTION

[0030] Various embodiments of the present disclosure provide a method of strapping a load, a strapping machine for strapping a load, and a pallet with strap channels.

[0031] FIGS. 1A and 1B illustrate one embodiment of a pallet 100 for supporting goods. The pallet 100 is sized and shaped to receive goods and to easily store and transport the goods from one location to another. The pallet 100 includes a top deck 102, a base 104, and a plurality of spacers 106. The plurality of spacers 106 extend between the top deck 102 and the base 104 to separate the top deck 102 and the base 104 from each other.

[0032] In some embodiments, the top deck 102 includes a plurality of openings 124. The openings 124 could be uniform throughout the top deck 102. The openings 124 could also differ across the top deck 102. The openings 124 could be round, square, rectangular, lobular, abstract in shape, or the like. In some embodiments, the pallet 100 includes tine-receiving openings 122 in the edges of the pallet 100 that are shaped and spaced to receive forks from a forklift such that the forks from the forklift enter the tine-receiving openings 122 and lift the pallet 100 by contacting a lower surface of the top deck 102. In some embodiments, the top deck 102, the base 104, and the plurality of spacers 106 define the tine-receiving openings 122. In some embodiments, the tine-receiving openings 122 extend across the entire pallet 100.

[0033] The base 104 includes a bottom deck 108 that has an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, and first and second side edges that are substantially parallel to each other and extend from the front edge to the back edge. A first set of strap channels 110 is defined in the underside of the bottom deck 108. The first set of strap channels 110 extends from the front edge of the bottom deck 108 to the back edge of the bottom deck 108. In some embodiments, a first side strap channel 110A of the first set of strap channels 110 is adjacent to a first side 114 of the pallet 100 and a second side strap channel 110B of the first set of strap channels 110 is adjacent to a second side 116 of the pallet 100. Also, defined in the underside of the bottom deck 108 is second set of strap channels 112. The second set of strap channels 112 extends from the first side edge of bottom deck 108 that is located on the first side 114 of the pallet 100 to the second side edge of bottom deck 108 that is located on the second side 116 of the pallet 100. In some embodiments, a front strap channel 112A of the second set of strap channels 112 is adjacent to a front side 118 of the pallet 100 and a back strap channel 112B of the second set of strap channels 112 is adjacent to a back side 120 of the pallet 100. In some embodiments, the first side strap channel 110A of the first set of strap channels 110 and the second side strap channel 110B of the first set of strap channels 110 are transverse to the front strap channel 112A of the second set of strap channels and the back strap channel 112B of the second set of strap channels 112. In some embodiments, each strap channel is shaped largely like a square, a rectangle, an ellipse, or any other elongated shape. In some embodiments, each strap channel is non-continuous in its perimeter, such as a C-shaped or a U-shaped channel having an upper side, a first side edge, and a second side edge. As such, there is no lower side of each strap channel separating an inner portion of the strap channel from the ground. In some embodiments, each strap channel is between 20 mm and 30 mm wide, such as 25 mm wide. In some embodiments, each strap channel is larger than 30 mm wide. In some embodiments each exit from the strap channel comprises an edge having a curved surface that wraps around from an underside of the bottom deck 108 onto the front edge, the back edge substantially parallel to the front edge, and the first and second side edges that are substantially parallel to each other of the base 104 such that the strap does not encounter any sharp, 90 degree edges when being tensioned around the load.

[0034] In some embodiments, the first side strap channel 110A of the first set of strap channels 110 and the second side strap channel 110B of the first set of strap channels 110 are positioned outside of tine-receiving openings 122 such that the forks from the forklift do not interfere with the strap channels. For instance, the first side strap channel 110A of the first set of strap channels 110 and the second side strap channel 110B of the first set of strap channels 110 are laterally spaced apart from the tine-receiving openings 122, each between the tine-receiving openings 122 and a respective side of the pallet 100, such that a strap does not extend across the tine-receiving openings 122 after the strapping process is complete. Similarly, in some embodiments, the front strap channel 112A of the second set of strap channels 112 and the back strap channel 112B of the second set of strap channels 112 are positioned outside of tine-receiving openings 122 such that the forks from the forklift do not interfere with the strap channels. In some embodiments, the first side strap channel 110A and the second side strap channel 110B are parallel with the tine-receiving openings 112.

[0035] FIGS. 2A and 2B illustrate an embodiment of a pallet 200 for supporting goods. The pallet 200 includes a top deck 202, a base 204, and a plurality of spacers 206. The plurality of spacers 206 are two or more spacers that extend between the top deck 202 and the base 204 to separate the top deck 202 and the base 204 from each other.

[0036] The base 204 includes a bottom deck 208 that has an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, and first and second side edges that are substantially parallel to each other and extend from the front edge to the back edge. In the front edge of the bottom deck 208 are the first set of strap channels 210, comprising three strap channels in this embodiment. The first set of strap channels 210 extend from the front edge of the bottom deck 208 to the back edge of the bottom deck 208. In some embodiments, a first side strap channel 210A of the first set of strap channels 210 is adjacent to a first side of the pallet 200, a second side strap channel 210B of the first set of strap channels 210 is adjacent to a second side of the pallet 200, and a center strap channel 210C of the front strap channels 200 is adjacent to a center of a front edge of the pallet 200. Also, in the first side edge of the bottom deck 208 are a second set of strap channels 212. The second set of strap channels 212 extend from the first side edge of the bottom deck 208 that is located on the first side of the pallet 200 to the second side edge of the bottom deck 208 that is located on the second side of the pallet 200. In some embodiments, a front strap channel 212A of the second set of strap channels 212 is adjacent to a front side of the pallet 200, a back strap channel 212B of the second set of strap channels 212 is adjacent to a back side of the pallet 200, and a center strap channel 212C of the second set of strap channels 212 is adjacent to a center of a side edge of the pallet 200.

[0037] Any of the pallets described in FIGS. 1 and 2 with strap channels on an underside of the pallet solve the above problems. The pallets with strap channels described herein can be strapped by strapping machines without the use of a deployable strap guide. Removing the deploy able strap guide from a strapping machine reduces cycle time for strapping loads, which increases throughput (i.e., the number of loads the strapping machine can strap in a given time period). Further, removing the deploy able strap guide from a strapping machine reduces a potential failure mode of the strapping machine, which increases the reliability of the strapping machine. In addition, because the pallets described in FIGS. 1 and 2 have strap channels on an underside of the pallet for the strap to occupy, the strap does not contact the ground and risk getting snagged or contact a forklift and/or pallet jack when moving the load.

[0038] FIGS. 3A-3F show one embodiment of a strapping machine 300 for strapping a load. The strapping machine 300 includes a frame 302. The frame 302 is configured to support some (or all) of the other components of the strapping machine 300. In this example embodiment, the frame 302 includes a base 310, first and second spaced-apart upstanding legs 304 and 306, a connector 308 that spans and connects the upper ends of the first and second legs 304 and 306, and a lower connector 318 embedded into the base 310 and connecting the lower ends of the first and second legs 304 and 306. The load supporter 312 is positioned atop the base 310, between the first and second legs 304 and 306, and below the connector 308 of the frame 302. The load supporter 312 is configured to support loads as they are strapped by and as they move through the strapping machine 300. The load supporter 312 includes a support surface 314 on which the loads are positioned during strapping and over which loads move as they move through the strapping machine 300. In this example embodiment, the support surface 314 includes multiple rollers that facilitate movement of the load through the strapping machine 300. The rollers may be driven or undriven. In some embodiments, the support surface 314 includes a driven conveyor instead of rollers. In some embodiments, the support surface 312 includes a chain conveyer instead of rollers.

[0039] The strapping machine 300 also includes a strap chute 316 that circumscribes the support surface 314 by running on the inner surface of first and second spaced-apart upstanding legs 304 and 306, the connector 308, and the lower connector 318, and the strap chute 316 defines a strap path that the strap follows when fed through the strap chute 316 and from which the strap is removed when retracted. The radially inward wall of the strap chute 316 is formed from multiple gates that are spring biased to a closed position that enables the strap to traverse the strap path when fed through the strap chute 316.

[0040] This is merely one example of a configuration of components that form the frame 302, and any other suitable configuration of any other suitable components may form the frame 302 in other embodiments. In some embodiments, strap chutes described herein can enable strapping on the outside of a pallet while elevating the strap off of the ground, which may improve the stability of the pallet and/or may reduce damage of the strap during transit.

[0041] Further, strapping machine 300 includes strapping module 320 and strap dispenser 322. The strapping module 320 includes a strapping head and a controller. In some embodiments, the controller includes a processing device (or devices) communicatively connected to a memory device (or devices). For instance, in some embodiments, the controller is a programmable logic controller. In some embodiments, the processing device includes any suitable processing device such as, but not limited to, a general-purpose processor, a special-purpose processor, a digital-signal processor, one or more microprocessors, one or more microprocessors in association with a digital-signal processor core, one or more application-specific integrated circuits, one or more field-programmable gate array circuits, one or more integrated circuits, and/or a state machine. In some embodiments, the memory device includes any suitable memory device such as, but not limited to, read-only memory, random-access memory, one or more digital registers, cache memory, one or more semiconductor memory devices, magnetic media such as integrated hard disks and/or removable memory, magneto-optical media, and/or optical media.

[0042] In some embodiments, the strapping head of the strapping module 320 includes a feed module configured to feed the strap supply 324 from the strap dispenser 322, a tensioning module configured to tension the strap supply around a load, and a sealing module configured to hold a leading strap end of the strap supply 324, cut a strap from the strap supply 324 to form a trailing strap end of the strap, and connect the leading strap end to the trailing strap end. In some embodiments, the controller of the strapping module 320 is configured to control the feed module to feed the strap supply 324 from the strapping head through a strap path defined by the strap chute 316, control the tensioning module to tension the strap around a load, and control the sealing module to hold the leading strap end, form the trailing strap end, and connect the leading strap end to the trailing strap end to form a tensioned strap loop around the load.

[0043] This is merely one example strapping head, and the strapping machine 300 may include any suitable modular strapping head or non-modular strapping head (i.e., a strapping head that is not comprised of independently removable and replaceable feed and sealing modules). The manner of attaching the leading and trailing strap ends to one another depends on the type of strapping machine and the type of strap. Certain strapping machines configured for plastic strap include strapping heads with friction welders, heated blades, or ultrasonic welders configured to attach the leading and trailing strap ends to one another. Some strapping machines configured for plastic strap or metal strap include strapping heads with jaws that mechanically deform (referred to as crimping in the industry) or cut notches into (referred to as notching in the industry) a seal element positioned around the leading and trailing strap ends to attach them to one another. Other strapping machines configured for metal strap include strapping heads with punches and dies configured to form a set of mechanically interlocking cuts in the leading and trailing strap ends to attach them to one another (referred to in the strapping industry as a sealless attachment). Still other strapping machines configured for metal strap include strapping heads with spot, inert-gas, or other welders configured to weld the leading and trailing strap ends to one another.

[0044] In some embodiments, the controller is operably connected to the support surface 314 such that the controller directs the support surface 314 to move a load to a strapping area 350 on strapping machine 300. The load comprises a pallet 330 for supporting goods 344. The pallet 330 may take the same or similar form as the pallet 100, may include any combination of components of the pallet 100, or may include a top deck 332, a base 334, and a plurality of spacers 336, as illustrated. The plurality of spacers 336 extend between the top deck 332 and the base 334 to separate the top deck 332 and the base 334 from each other. The base 334 includes a bottom deck 338 that is similar in form to the bottom deck 108. In the front edge of the bottom deck 338 are a strap channel 340 and a strap channel 342.

[0045] The controller then stops the load in the strapping area 350 such that the strap chute 316 circumscribes the load such that strap channel 340 of the pallet 330 is aligned with the lower connecting portion 318, as is illustrated in FIG. 3C. When the load is stopped, strap supply 324 is fed through the strap chute 316. The strap is then retracted from the strap chute 316 and into the strap channel 340 of the pallet 330 and around the load. The strap is then tensioned around the load.

[0046] In some embodiments, the strap chute 316 comprises two C-shaped channels coupled at a hinge joint, as shown in FIGS. 3E and 3F. The two sides of the strap chute 316 could be configured to be spaced such that strap supply 324 is retained between the two sides of the strap chute 316, as is shown in FIG. 3E. Once it is determined that the load is aligned with the lower connecting portion 318, the two sides of the strap chute 316 can be hinged open such that the strap supply 324 is released from the bounds of the strap chute 316 into the strap channel 340 of the pallet 300, as is shown in FIG. 3F.

[0047] In some embodiments, the controller is configured to communicate with one or more sensors so as to align the strap channel 340 with the lower connection portion 318. For instance, in some embodiments, a light sensor could be utilized such that, when in operation, a light guide from the light sensor could be in communication with the controller to align the strap channel 340 with the lower connecting portion 318. In some embodiments, a position sensor could be in communication with the controller such that the position sensor could detect when the strap channel 340 is aligned with the lower connecting portion 318 and direct the controller to stop the pallet 330. In some embodiments, the strap is aligned with the lower connecting portion 318 when the strap in the strap chute 316 is fully between a first side and a second side of a strap channel such that the strap is within the outer bounds of the strap channel. For instance, the strap is aligned with the lower connection portion 318 when the strap is retracted and pulled from the strap chute and onto the load, the strap is within the strap channel.

[0048] Further, the controller moves the load already strapped through strap channel 340 to a strapping area 360 on strapping machine 300. The controller then stops the load in the strapping area 360 such that the strap chute 316 circumscribes the load such that strap channel 342 of pallet 330 is aligned with the lower connecting portion 318, as is illustrated in FIG. 3D. When the load is stopped, strap supply 324 is fed through the strap chute 316. The strap is then retracted from the strap chute 316 and into the strap channel 342 of the pallet 330 and around the load. The strap is then tensioned around the load.

[0049] In some embodiments, the strapping machine 300 includes one or more sensors configured to interface with a remote controller that is communicatively and operably connected to the strapping machine. In such embodiments, the remote controller is not part of the strapping module 320, but is configured to interface with portions of the strapping machine 300. The remote controller could take the same or similar form as any embodiment of the controller of the strapping module 320.

[0050] In some embodiments, the remote controller moves the load on the load supporter 312 until one or more sensors on the strapping machine 300 detects that the load is in the correct strapping area. In some embodiments, the strapping machine 300 includes a stopper configured to stop the load. As such, the remote controller moves the load on the load supporter 312 until the load interfaces with the stopper of the strapping machine 300.

[0051] In some embodiments, strapping machine 300 includes a second strap chute downstream of the first strap chute that has similar or the same components as the first strap chute and is configured to receive strap supply from a second strap dispenser. As such, the controller could be configured to move a load to a strapping area on strapping machine 300 such that strap channel 340 aligns with the first strap chute and strap channel 342 aligns with the second strap chute. The first strapping head is then fed strap from the first strap dispenser having a roll of strap supply by the controller through a first strap path defined by the first strap chute simultaneously as the second strapping head is then fed strap from the second strap dispenser having a second roll of strap supply by the controller through a second strap path defined by the second strap chute. The controller then simultaneously would tension a first strap around the load through channel 340 and a second strap around the load through channel 342.

[0052] Any of the above embodiments can be performed by three or more strap chutes such that an equivalent number of straps are formed through an equivalent number of strap channels in a pallet as the number of strap chutes of the strapping machines.

[0053] FIG. 4 illustrates a method 400 for strapping a load. At block 402, the method comprises moving the load to a strapping area on a load supporter of a strapping machine. The load in this case could be any embodiment described in FIGS. 1 and 2 and the strapping machine can be any embodiment described in FIGS. 3A-3D. In some examples, the load comprises a pallet and goods supported by the pallet. As such, the pallet comprises a base and a top deck connected to the base and has opposing first and second ends and opposing first and second sides transverse to the first and second ends such that an underside of the base defines a first strap channel adjacent the first end of the pallet and a second strap channel adjacent the second end of the pallet and the first and second strap channels extend from the first side to the second side.

[0054] At block 404, the method comprises stopping the load in the strapping area so a strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter. At block 406, the method comprises feeding, via a strapping head of the strapping machine, strap from a strap supply through the strap chute along a strap path defined by the strap chute. At block 408, the method comprises retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the first strap channel. The strapping head retracts the strap by exerting a pulling force on the strap, and the pulling force overcomes the biasing force of the springs and causes the gates to pivot to an open position, thereby releasing the strap from the strap chute so the strap contacts the load as the strapping head continues to retract the strap. At block 410, the method comprises tensioning, via the strapping head, the strap around the load.

[0055] In some embodiments, the underside of the base comprises an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, and first and second side edges which are substantially parallel to one another. In such embodiments, the first strap channel adjacent the first end of the pallet and the second strap channel adjacent the second end of the pallet extend from the first side edge to the second side edge of the pallet. In some embodiments, the strap from the strap supply is fed by the strapping head through the strap chute before the load stops at the stopping area. With the strap pre-fed through the strap chute, the time for strapping a load once the load is stopped in the strapping area is further reduced.

[0056] In some embodiments, the method 400 reduces the cycle time of strapping a load by about 10 seconds compared with strapping a load with a strapping machine having a deploy able strap guide. In some embodiments, the method 400 results in around a 35% reduction in cycle time of strapping a load compared with strapping a load with a strapping machine having a deployable strap guide.

[0057] FIGS. 5A-5D illustrate an example of strapping a load 510 according to the method illustrated in FIG. 4. The pallet of the load 510 may take the same or similar form as the pallet 100 or may include any combination of components of the pallet 100. The strapping machine 500 may take the same or similar form as strapping machine 300, may include any combination of components of strapping machine 300, or may include a frame 504 having a base 502, and connector 508 that spans and connects the upper ends of the first and second legs, as illustrated in FIGS. 5A-5D.

[0058] In FIG. 5A, the load, having the pallet 510 and goods 518, is on top of the load supporter 512 of the strapping machine 500 and is approaching a strapping area of the strapping machine 502. The load will continue to move across the rollers of load supporter 512 until the load is in strapping area 520 on the load supporter 512 of the strapping machine 500, as illustrated in FIG. 5B. The load will then be stopped in the strapping area 520 such that the strap chute of strapping machine 500 circumscribes the load such that a first strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the first strap channel, and tensions a strap 514 around the load.

[0059] Further, the load will continue to move across the rollers of load supporter 512 until the load is in strapping area 530 on the load supporter 512 of the strapping machine 500, as illustrated in FIG. 5C. The load will then be stopped in the strapping area 530 such that the strap chute of strapping machine 500 circumscribes the load such that a second strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the second strap channel, and tensions a strap 516 around the load. FIG. 5D illustrates a fully strapped load having straps 514 through first strap channel and 516 through second strap channel.

[0060] In some embodiments, the underside of the base defines a third strap channel positioned at a center of the pallet. The load could be configured to move across the rollers of load supporter 512 until the load is in a third strapping area on the load supporter 512 of the strapping machine 500. The load will then be stopped in the third strapping area such that the strap chute of strapping machine 500 circumscribes the load such that the third strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the third strap channel, and tensions a third strap around the load.

[0061] In some embodiments, the strapping machine could be configured to rotate the load around 90 degrees such that the first side edge is nearest the strapping head 506. The load will again move across the rollers of load supporter 512 until the load is in a third strapping area on the load supporter 512 of the strapping machine 500. The load will then be stopped in the third strapping area such that the strap chute of strapping machine 500 circumscribes the load such that a front strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the front strap channel, and tensions a strap around the load, crossing over the two straps already over the load in a perpendicular direction.

[0062] Further, the load will continue to move across the rollers of load supporter 512 until the load is in a fourth strapping area on the load supporter 512 of the strapping machine 500. The load will then be stopped in the fourth strapping area such that the strap chute of strapping machine 500 circumscribes the load such that a back strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the back strap channel, and tensions a strap around the load, crossing over the two straps already over the load in a perpendicular direction.

[0063] In some embodiments, the load is on top of the load supporter 512 of the strapping machine 500 and is approaching a strapping area of the strapping machine 502. The load will continue to move across the rollers of load supporter 512 until the load is in strapping area 520 on the load supporter 512 of the strapping machine 500, as illustrated in FIG. 5B. The load will then be stopped in the strapping area 520 such that the strap chute of strapping machine 500 circumscribes the load such that a first strap channel of the pallet portion of the load is aligned with a portion of the strap chute extending across the load supporter 512. A strapping head 506 of the strapping machine 500 feeds strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracts the strap from the strap chute and onto the load so part of the strap is received in the first strap channel, and tensions a strap 514 around the load.

[0064] Further, the load will continue to move across the rollers of load supporter 512 until the load is in a second strapping area on the load supporter 512. The load will then be stopped in the second strapping area such that a strap chute of a second strapping machine circumscribes the load such that a second strap channel of the pallet portion of the load is aligned with a portion of the strap chute of the second strapping machine extending across the load supporter 512. A strapping head of the second strapping machine feeds strap from a strap supply through the strap chute of the second strapping machine along a strap path defined by the strap chute of the second strapping machine, retracts the strap from the strap chute of the second strapping machine and onto the load so part of the strap is received in the second strap channel, and tensions a second strap around the load.

[0065] In some embodiments, the underside of the base defines a third strap channel positioned at a center of the pallet. The load could be configured to move across the rollers of load supporter 512 until the load is in a third strapping area on the load supporter 512. The load will then be stopped in the third strapping area such that a strap chute of a third strapping machine circumscribes the load such that a third strap channel of the pallet portion of the load is aligned with a portion of the strap chute of the third strapping machine extending across the load supporter 512. A strapping head of the third strapping machine feeds strap from a strap supply through the strap chute of the third strapping machine along a strap path defined by the strap chute of the third strapping machine, retracts the strap from the strap chute of the third strapping machine and onto the load so part of the strap is received in the third strap channel, and tensions a third strap around the load.

[0066] In some embodiments, the load is on top of the load supporter 512 of the strapping machine 500 and is approaching a strapping area of the strapping machine 502. The load will continue to move across the rollers of load supporter 512 until the load is in a strapping area on the load supporter 512 of the strapping machine 500. The load will then be stopped in the strapping area 520 such that a first strap chute of strapping machine 500 circumscribes the load and aligns with a first strap channel of the pallet portion of the load and a second strap chute of strapping machine 500 circumscribes the load and aligns with a second strap channel of the pallet portion of the load. A strapping head of the strapping machine 500 feeds strap from a strap supply through the first strap chute along a strap path defined by the first strap chute, retracts the strap from the first strap chute and onto the load so part of the strap is received in the first strap channel, and tensions a first strap 514 around the load and feeds strap from a strap supply through the second strap chute along a strap path defined by the second strap chute, retracts the strap from the second strap chute and onto the load so part of the strap is received in the second strap channel, and tensions a second strap 516 around the load.

[0067] Pallets with strap channels described herein can be strapped without a strapping machine. In some embodiments, straps are fed using a handheld device to feed the strap through the strap channel. For example, a first strap is fed by a strapping tool through the first channel of the pallet, over the palletized goods, and connected to itself to form a first strap around the load. A second strap is then fed by the strapping tool through the second channel of the pallet, over the palletized goods, and connected to itself forming a second strap around the load.

[0068] In some embodiments, straps are fed by hand using a strap material that is rigid enough to be fed without a tool. For example, a first strap is fed by hand through the first channel of the pallet, over the palletized goods, and connected to itself forming a first strap around the load. A second strap is fed by hand through the second channel of the pallet, over the palletized goods, and connected to itself forming a second strap around the load.

[0069] FIGS. 6A-6B illustrate a strapped load, namely, a pallet 600 supporting goods 626. FIG. 6A shows the pallet 600 and goods 626 strapped in one direction through strap channels 610 and 612 and in a second direction going through strap channels 614 and 616. In FIG. 6A, strap 618 surrounds the pallet 600 and goods 626 and goes through strap channel 610. Strap 620 surrounds the pallet 600 and goods 626 and going through strap channel 612. Strap 622 surrounds the pallet 600 and goods 626 and goes through strap channel 614. Strap 624 surrounds the pallet 600 and goods 626 and goes through strap channel 616.

[0070] The pallet 600 may take the same or similar form as the pallet 100, may include any combination of components of the pallet 100, or may include a top deck 602, a base 604, and a plurality of spacers 606, as illustrated. The plurality of spacers 606 extend between the top deck 602 and the base 604 to separate the top deck 602 and the base 604 from each other. The base 604 includes a bottom deck 608 that is similar in form to the bottom deck 108. In the underside of the bottom deck 608 are the strap channels 610, 612, 614, and 616.

[0071] FIGS. 7A-7B illustrate a strapped load, namely, a pallet 700 supporting goods 726. FIG. 7A shows the pallet 700 and goods 726 strapped in one direction through strap channels 710, 712, and 714 and in a second direction going through strap channels 716, 718, and 720. In FIG. 7A, strap 722 surrounds the pallet 700 and goods 726 and goes through strap channel 710. Strap 724 surrounds the pallet 700 and goods 726 and going through strap channel 712. Strap 726 surrounds the pallet 700 and goods 726 and going through strap channel 714. Strap 728 surrounds the pallet 700 and goods 726 and going through strap channel 716. Strap 730 surrounds the pallet 700 and goods 726 and going through strap channel 718. Strap 732 surrounds the pallet 700 and goods 726 and going through strap channel 720.

[0072] The pallet 700 may take the same or similar form as the pallet 200, may include any combination of components of the pallet 200, or may include a top deck 702, a base 704, and a plurality of spacers 706, as illustrated. The plurality of spacers 706 extend between the top deck 702 and the base 704 to separate the top deck 702 and the base 704 from each other. The base 704 includes a bottom deck 708 that is similar in form to the bottom deck 208. In the underside of the bottom deck 708 are the strap channels 710, 712, 714, 716, 718, and 720.

[0073] In some embodiments described in FIGS. 1-7B, a strap channel has a perimeter that is continuous. In some embodiments, a strap channel has a perimeter that has one or more openings or discontinuities. Also, in some embodiments described in FIGS. 1-7B, a pallet is manufactured/formed as a singular piece, requiring no connections. In other embodiments, a pallet is manufactured in two or more pieces and connected through connecting mechanisms, such as a top deck and a bottom deck with a plurality of spacers extending vertically upward from the bottom deck such that the top deck is connected to a top portion of the plurality of spacers by way of a connecting mechanism. In other embodiments, a pallet is manufactured in two or more pieces and connected through connecting mechanisms, such as a top deck with a plurality of spacers extending vertically downward from the top deck and a bottom deck such that the bottom deck is connected to a bottom portion of the plurality of spacers by way of a connecting mechanism. In some embodiments, a pallet is reversible.

[0074] Thus, in various embodiments, the present disclosure provides a method of strapping a load comprising goods supported by a pallet. The method comprises moving the load to a strapping area on a load supporter of a strapping machine. The pallet comprises a base and a top deck connected to the base and has opposing first and second ends and opposing first and second sides transverse to the first and second ends such that an underside of the base defines a first strap channel adjacent the first end of the pallet and a second strap channel adjacent the second end of the pallet and the first and second strap channels extend from the first side to the second side. The method further comprises stopping the load in the strapping area so a strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter. Further, the method comprises feeding, via a strapping head of the strapping machine, strap from a strap supply through the strap chute along a strap path defined by the strap chute, retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the first strap channel, and tensioning, via the strapping head, the strap around the load.

[0075] In various such embodiments of the method of strapping the load, feeding the strap includes feeding, via the strapping head, the strap from the strap supply through the strap chute before the load stops at the strapping area.

[0076] In various such embodiments of the method of strapping the load, the method further includes moving the load to a second strapping area on the load supporter of the strapping machine; stopping the load in the second strapping area so the strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via the strapping head, strap from the strap supply through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the second strap channel; and tensioning, via the strapping head, the strap around the load.

[0077] In various such embodiments of the method of strapping the load, the underside of the base further defines a third strap channel positioned at a center of the pallet, and the method further includes moving the load to a third strapping area on the load supporter of the strapping machine; stopping the load in the third strapping area so the strap chute of the strapping machine circumscribes the load and so the third strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via the strapping head, strap from the strap supply through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the third strap channel; and tensioning, via the strapping head, the strap around the load.

[0078] In various such embodiments of the method of strapping the load, the method further includes moving the load to a second strapping area on a load supporter of a second strapping machine; stopping the load in the second strapping area so a strap chute of the second strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via a strapping head of the second strapping machine, strap from a strap supply of the second strapping machine through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head of the second strapping machine, the strap from the strap chute and onto the load so part of the strap is received in the second strap channel; and tensioning, via the strapping head of the second strapping machine, the strap around the load.

[0079] In various such embodiments of the method of strapping the load, the underside of the base further defines a third strap channel positioned at a center of the pallet, and the method further includes moving the load to a third strapping area on a load supporter of a third strapping machine; stopping the load in the third strapping area so a strap chute of the third strapping machine circumscribes the load and so the third strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter; feeding, via a strapping head of the third strapping machine, strap from a strap supply of the third strapping machine through the strap chute along a strap path defined by the strap chute; retracting, via the strapping head of the third strapping machine, the strap from the strap chute and onto the load so part of the strap is received in the third strap channel; and tensioning, via the strapping head of the third strapping machine, the strap around the load.

[0080] In various such embodiments of the method of strapping the load, the method further includes stopping the load so a first strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the first strap chute extending across the load supporter and so a second strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the second strap chute extending across the load supporter.

[0081] In various such embodiments of the method of strapping the load, the underside of the base further comprises an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, first and second side edges which are substantially parallel to one another such that the first strap channel adjacent the first end of the pallet and the second strap channel adjacent the second end of the pallet extend from the first side to the second side.

[0082] In various other embodiments, the disclosure further provides a strapping machine for strapping a load that includes a load supporter configured to support the load such that the load includes a pallet and goods supported by the pallet. The pallet includes a base and a top deck connected to the base and has opposing first and second ends and opposing first and second sides transverse to the first and second ends such that an underside of the base defines a first strap channel adjacent the first end of the pallet and a second strap channel adjacent the second end of the pallet and the first and second strap channels extend from the first side to the second side. The strapping machine also includes a strapping head, a strap chute defining a strap path and configured to receive strap from a strap supply, and a controller. The controller is operably connected to the strapping head and configured to move the load to a strapping area on the load supporter, stop the load in the strapping area so the strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter, feed, via a strapping head of the strapping machine, strap from a strap supply through the strap chute along a strap path defined by the strap chute, retract, via the strapping head, the strap from the strap chute and onto the load so part of the strap is received in the first strap channel, and tension, via the strapping head, the strap around the load.

[0083] In various such embodiments of the strapping machine, the controller is further configured to move the load to a strapping area on the load supporter and stop the load in the strapping area so the strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter.

[0084] In various such embodiments of the strapping machine, the controller is further configured to move the load to a second strapping area on the load supporter and stop the load in the second strapping area so the strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter.

[0085] In various such embodiments of the strapping machine, the strapping machine includes a feed module configured to feed the strap, a tensioning module configured to tension the strap, and a sealing module configured to hold a leading strap end of the strap, cut the strap from the strap supply to form a trailing strap end of the strap, and connect the leading strap end to the trailing strap end.

[0086] In various such embodiments of the strapping machine, the controller is further configured to control the feed module to feed the strap from the strapping head through the strap chute along the strap path, control the tensioning module to tension the strap around the load, and control the sealing module to hold the leading strap end, form the trailing strap end, and connect the leading strap end to the trailing strap end to form a tensioned strap loop.

[0087] In various such embodiments of the strapping machine, the strapping machine further includes a second strap chute configured to receive strap from the strap supply.

[0088] In various such embodiments of the strapping machine, the controller is further configured to feed a first strap from the strap supply through the strap chute along a strap path defined by the strap chute, feed a second strap from the strap supply through the second strap chute along a second strap path defined by the second strap chute, and tension the first strap and the second strap around the load.

[0089] In various such embodiments of the strapping machine, the controller is further configured to move the load to a strapping area on the load supporter and stop the load in the strapping area so the strap chute of the strapping machine circumscribes the load and so the first strap channel of the pallet is aligned with a portion of the strap chute extending across the load supporter and so the second strap chute of the strapping machine circumscribes the load and so the second strap channel of the pallet is aligned with a portion of the second strap chute extending across the load supporter.

[0090] In various such embodiments of the strapping machine, the strapping machine further includes a plurality of strap chutes configured to receive strap from the strap supply.

[0091] In various such embodiments of the strapping machine, the strap chute has a first side and a second side such that the first side and the second side are hinged together at a hinge joint. The first side and the second side are configured to retain the strap supply until the first side and the second side are hinged apart at the hinge joint to release the strap supply.

[0092] In various other embodiments, the disclosure further provides a pallet for supporting goods, the pallet including a top deck, a base having a bottom deck having an upper surface, a lower surface, a front edge, a back edge substantially parallel to the front edge, first and second side edges which are substantially parallel to one another such that the bottom deck comprises two or more front strap channels configured to receive strap extending from the front edge to the back edge such that a first side strap channel of the two or more front strap channels is adjacent to the first side edge and a second side channel of the two or more front strap channels is adjacent to the second side edge and two or more side strap channels configured to receive strap extending from the first side edge to the second side edge such that a front strap channel of the two or more side strap channels is adjacent to the front edge and a back strap channel of the two or more side strap channels is adjacent to the back edge, and a plurality of spacers extending substantially perpendicularly downward from the top deck to the base and separating the top deck and the base.

[0093] In various such embodiments of the pallet, the top deck includes a plurality of openings.

[0094] In various such embodiments of the pallet, the pallet further including a plurality of fork inlets, wherein each fork inlet is configured to receive a fork of a forklift.