Note: Descriptions are shown in the official language in which they were submitted.
CA 02471697 2004-06-21
Docket No. 3158 PUS
PALLET SUPPORT UNIT
BACKGROUND OF THE INVENTION
[0001] This present invention relates generally to pallets and more
particularly to a
pallet support unit.
[0002] Pallets are used to store and transport goods. Pallets maintain the
goods at a
distance above the floor such that they can be readily lifted and moved by a
forklift. After the
goods are unloaded, the empty pallets are typically returned to tle first
location for reuse.
[0003] Plastic pallets are usually lighter than wooden pallets and some
plastic pallets
are designed to be nestable, such that each pallet at least pai~ially fits
within another empty
pallet, to minimize the space required for storing and transporting the empty
pallets. However, a
significant amount of effort and space is still needed to store, return and
reuse the pallets.
[0004] The use of multiple, plastic supports has been proposed. The disposable
plastic support includes a load-bearing upper surface and a floor-contacting
lower surface. A
plurality of legs extend at an angle outwardly from the upper surface to the
lower surface and
may include openings for receiving a forklift between each adjacent pair of
legs. A plurality
of similar or identical supports are then arranged to support the goods at a
distance above the
floor. These supports may be formed inexpensively enough that they can. be
used once to
transport goods from their origin to destination and then, instead of
returning them, they can
be recycled. However, the legs of such supports may not be substantial enough
to withstand
impact from a forklift. Therefore, a pallet support unit with legs with
improved impact
resistance is desired.
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CA 02471697 2004-06-21
Docket No. 3158 PUS
SUMMARY OF THE INVENTION
j0005] The present invention provides a pallet support unit comprising a
plastic support with improved leg strength, and impact resistance.
[0006] The pallet support unit according to the present invention includes
legs, each of which comprises multiple angled wallstock to improve impact
strength. In a
preferred embodiment, each leg includes a plurality of 90 degree angles
oriented in alignment
with each opening between each adjacent pair of legs. Each leg may include
three 90 degree
angles forming a generally "W-shaped" cross-section. The leg may further
include ribs
protruding outwardly from outer surfaces to limit the nesting of stacked
supports when not in
use.
j0007] In another embodiment, a plurality of supports are joined by a
plurality
of connectors extending therebetween, integrally molded as a single structure.
Facing
openings of adjacent supports are connected by a pair of side connector walls
each formed
continuously with one section of a leg. An upper connector wall connects the
pair of side
connector walls.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Other advantages of the present invention can be understood by
reference to the following detailed description when considered in connection
with the
accompanying drawings wherein:
[0009] Figure I is a perspective view of a first embodiment of the pallet
support unit according to the present invention.
[0010] Figure 2 is a perspective view of one of the support units shown in
Figure 1.
2
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CA 02471697 2004-06-21
Docket No. 3158 PUS
(0011] Figure 3 is a second embodiment of the pallet support unit according to
the present invention.
[0012] Figure 4 is a partial section of an alternative embodiment of assembly
50
shown in Figure 3.
DETAILED DESCRIPTTON OF THE PREFERRED EMBODIMENT
[0013] Figure 1 illustrates a pallet support unit 10 supporting a load 12 of
layers
of goods 13. The pallet support 10 includes a plurality of spaced apart
supports 14 generally
arranged in a two-by-two matrix. All of the supports 14 are substantially
similar, and may be
injection molded of high-density polyethylene, or other plastic materials
suitable for the
application.
[0014] Figure 2 shows one of the support units 14, which has a generally
planar
upper member 16 having an upper surface 18 that defines a load-bearing
surface. A leg 20
extends downwardly at an angle of approximately 115 degrees outwardly from
each corner of
the upper member 16. The lower ends 22 of the legs 20 are connected by a lower
member
24, which is a peripheral flange 24 that extends around the periphery of the
support 14 that
provides strength to the legs 20 by preventing them from bending or deflecting
outwardly,
and also allow load to be transferred to the surface below. In one embodiment,
defined
between each adjacent pair of legs 20, and between the flange 24 and upper
member 16, an
opening 2b may be provided for receiving forklift tine.
[0015] In the support I4 according to the present invention, each leg 20
includes a
plurality of transverse wall sections 30a-d. In the preferred embodiment, each
of the wall
sections 30a-d extends perpendicularly or substantially perpendicularly to
each adjacent wall
section 30a-d. In order to provide increased resistance to impact from a
forklift tine, the outer
3
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CA 02471697 2004-06-21
Docket No. 3158 PUS
wall sections 30a and 30d, which are adjacent openings 26, are oriented in a
plane
perpendicular or substantially perpendicular to a plane defined by the opening
26 (i.e. the
plane substantially defined by the outer edges of upper member 16, wall
sections 30d, 30 a',
and the inner edge of the peripheral flange 24). Each leg 20 further includes
an inner wail
section 30b, 30c adjacent to and perpendicular to the outer wall sections 30a,
30d,
respectively, and perpendicular to one another. The result is a generally "W-
shaped" cross-
section for each leg 20. At a lower end of each inner wall section 30b, 30c an
outwardly
extending vertical rib 36 prevents the supports 14 from nesting within one
another too tightly
when stacked between uses.
[0016] In use, the supports 14 are arranged in a spaced-apart arrangement on a
floor with the openings 26 of the supports 14 aligned to receive forklift
tines. Goods 13 are
then stacked on the supports 14 in an arrangement that will depend upon the
relative size,
weight or density of the goods 13 and the supports, and upon the number of
goods 13 to be
stacked thereon. One arrangement is illustrated in Figure 1. In some cases, a
sheet of
cardboard or other type of slip sheet may be included between the support
units 14 and
bottom layer of goods 13 for increased support and stability. In some cases,
it may be
desirable to wrap the goods 13 together in plastic or other packaging, or even
to wrap or
otherwise attach the support units 14 to the load 12 of goods 13.
[0017] The load of goods 13 may then be transported to its destination on
support
units 14, such as by forklift. In the event of an impact by the forklift tine
with one of the legs
20, the outer wall section 30a or 30d will provide increased strength, impact
resistance, and
help prevent the collapse of support unit 14. At the destination, the load of
goods 13 is
unloaded and/or sold and support units 14 can be stored by nesting them, each
one within
another. In this manner the unused supports 14 occupy a minimal amount of
space.
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CA 02471697 2004-06-21
Docket No. 3158 PUS
[0018] Figure 3 is a perspective view of a second embodiment of a pallet
assembly 50 according to the present invention. In this pallet assembly S0,
the four supports
14 are integrally molded as a single, unitary structure with each other and
with connectors 52.
Each connector 52 includes a pair of connector side walls 54, 56 extending
from and
continuous with the outer wall sections 30d, 30a that are adjacent the
openings 26 (not visible
in Figure 3) facing one another from adjacent supports 14. Each connector 52
further
includes an upper connector wall 58 connecting the two connector side walls
54, 56 and
continuous and co-planar with the upper members 16 of the supports 14. The
upper
connector wall 58 may include small openings 60 for drainage, ventilation and
to reduce
weight and material of the assembly S0. The peripheral flange 24 extends
outwardly from the
outer connector side wall 54.
[0019] Figure 4 is a partial section of an alternative embodiment of assembly
50
shown in Figure 3, wherein similar components are designated with like
reference numerals
having a prime (') suffix. As shown therein, pallet support assembly 50'
includes pallet
support units 14' having a generally cylindrical cross section in place of the
rectangular
design of the previous embodiment, such as those disclosed in US Patent
Application
Publication No. 2003/0047121A1, assigned to the assignee of the present
invention and
incorporated herein by reference. Units 14' include an upper section 16', a
lower flange 24',
and having legs 20' extending therebetween.. As in Figure 3, connectors 52'
extend between
laterally adjacent units 14' to form assembly 50'. Legs 20' may be corrugated
such that they
act as springs to assist in absorbing shock or load placed on the unit, to the
extent of which
depends on the material chosen, the number of corrugations, and the number,
size and
spacing of legs 20'. Fork truck tines may be received by the openings 26'
defined between
the legs 20'. Further, the lower edge 55' of side wall 54' may be raised
upwardly such that a
fork tine could be received under the side wall.
CA 02471697 2004-06-21
Docket No. 3158 PUS
{0020] While embodiments of the invention have been illustrated and described,
it
is not intended that these embodiments illustrate and describe all possible
forms of the
invention. Rather, the words used in the specification are vvords of
description rather than
limitation, and it is understood that various changes may be made without
departing from the
spirit and scope of the invention.
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