Note: Descriptions are shown in the official language in which they were submitted.
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A PALLET
Field of the Invention
The present invention relates to pallets and in particular to a multi-purpose
pallet having detachable components.
Background of the Invention
Pallets made of wood are typically used throughout the world for easy storing
and transporting of goods. These pallets are generally of a square shape
having an
upper and lower deck made of a series of wooden planks and at least two solid
wooden beams therebetween. The pallet is normally nailed together and includes
slots
within which a forklift's tines or other material handling devices can be
located for
lifting and moving the pallet.
Known pallets suffer from many disadvantages. For example; they are
expensive to manufacture; require repeated repair; are limited to standard
sizes; have
protruding fixings or connections; are limited in the amount they can carry;
are easy
to damage or break; are heavy; difficult to attach additional components when
required; absorb moisture, liquids and odours; are a fire risk; can have
termite and
insect contamination; splinter easily; the nails can loosen; have a short life
span and
the timber used is generally from hardwood forests. Of particular concern is
that wood
pallets damaged easily and the repair or replacement of the pallet is
expensive, time
consuming and it is usually easier to just discard the pallet. Further, wood
pallets
retain dirt and other undesirable substances which minimises their use in
contamination or hygienic areas such as the food or medical industries.
Metal and plastic pallets have also been developed. These types of pallets
have
many disadvantages similar to wood pallets.
Accordingly, there is a need for a lightweight metal pallet that has
releasably
connectable parts for easy maintenance and repair, overcomes debris and
contamination problems and includes no sharp edges.
The present invention has been developed to overcome or ameliorate some of
the disadvantages of the prior art, or at least to provide a useful
alternative.
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Summary of the Invention
Accordingly, there is provided a metal pallet having: a top deck of sheet
material; a bottom deck of sheet metal spaced from the top deck; at least two
longitudinally elongated bearers each formed of sheet metal and secured to and
extending transversely between the decks so that the top deck is supported on
the
bottom deck; and wherein each bearer has a first and a second longitudinally
extending bearer portion, with each portion being secured to said decks and
extending
separately transversely between said decks and wherein each portion has a
longitudinally extending top web secured to the top deck, a longitudinally
extending
bottom web secured to the bottom deck, a longitudinally extending central web
extending generally normal to said decks, and longitudinally extending
inclined web
portions securing the central web to the top and bottom webs, each inclined
web
portion being inclined to the decks by an acute angle.
There is also described a detachable-component metal pallet comprising: a
sheet metal top deck; a sheet metal bottom deck spaced apart from and
generally
parallel to the top deck; at least two elongate bearers, wherein the elongate
bearers are
positioned between the top and bottom decks such that they extend lengthwise
parallel
to the top and bottom decks, each elongate bearer comprising a first and a
second
portion extending lengthwise parallel to the top and bottom decks, where each
first
and second portion has a top web, a central web and a bottom web, and inclined
portions connect the top web to the central web and the central web to the
bottom
web, where the inclined portions aligned to the top and bottom decks at an
acute
angle; wherein the first and second portions of the elongate bearers are
aligned such
that the central webs of each first and second portion abut each other and are
oriented
perpendicularly to the top and bottom decks, the central webs being releasably
securable to each other via at least one fastener; wherein the top and bottom
webs of
the first and second portions are oriented generally parallel to the top and
bottom
decks, the top webs abutting and being releasably securable to the top deck
via at least
one fastener and the bottom webs abutting and being releasably securable to
the
3o bottom deck via at least one fastener, such that the top and bottom decks
are
releasably secured together and the top deck is supported on the bottom deck
via the
elongate bearers; and wherein the top deck, the bottom deck and the first and
second
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portions are all configured to be able to be detached and replaced by
replacement
components.
Preferably, the central webs of the first and second portions are releasably
securable together.
Preferably, the top and bottom webs are releasably securable to the decks.
Preferably, the webs are releasably securable to the decks and/or each other
by
fastening means.
Preferably, the fastening means are threaded fasteners.
Preferably, the pallet includes a plurality of holes for receiving each
fastening
means.
Preferably, the fastening means are welds or rivets.
Preferably, the pallet is of a generally rectangular configuration having a
front
edge, a rear edge and two side edges.
Preferably, at least one edge includes a cover plate.
Preferably, at least one elongate bearer includes a stiffener.
Preferably, at least one bearer includes an end cap.
Preferably, the top and/or bottom deck is of a profiled configuration.
Preferably, the profiled configuration are corrugations.
Preferably, the pallet includes sheet material secured to at least one deck.
Preferably, the pallet includes cavities for receipt of tines of a forklift or
other
handling equipment.
Preferably, the cavities are located on all sides of the pallet.
Brief Description of the Drawings
A preferred form of the present invention will now be described, by way of
example only, with reference to the accompanying drawings wherein:
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Figure 1 is a partial perspective view of a bearer for a pallet of an
embodiment of
the present invention;
Figure 2 is a perspective view of a pallet of an embodiment of the present
invention;
Figure 3 is a partial perspective view of the pallet of Figure 2 with
attachments;
Figure 4 is a partial side view of the pallet of Figure 2 with attachments.
Figures 5a to 5d are cross-sectional views of bearer embodiments for a pallet
of
the present invention;
Figures 6a to 6c are partial side views of embodiments of the invention
showing
io recesses for tines of a forklift;
Figures 7a and 7b are perspective views showing the four way openings of Figs.
6a to 6c; and
Figure 8 shows a cross-sectional view of an alternate embodiment of the pallet
of
Fig. 1.
Detailed Description of the Preferred Embodiments
There is disclosed herein a pallet 1 manufactured of metal typically
galvanised
steel or aluminium. The pallet 1 includes a top deck 5, a bottom deck 10 and
at least two
elongate bearers 15 securing the decks 5, 10 together. As best seen in Figures
1, 5a to 5d
and 8 each bearer 15 has a first portion 16 and a second portion 17 extending
separately
between the decks 5, 10 and having a top web 20 and a bottom web 25 connected
to a
central web 30 by inclined portions 35. In use, the webs 20, 25, 30 of the
first and second
portions 16, 17 are releasably securable to each other and the decks 5, 10 by
fastening
means 40 such as a threaded fastener which is typically located in holes 45.
In the
preferred form the central webs 30 are substantially vertical or normal to the
decks 5, 10.
Alternatively, the fastening means 40 could be a weld or rivet, the pallet 1
easily being
repaired by drilling out the weld or rivet, replacing the part and re-welding
or riveting.
Typically, the portions 16, 17 of the bearers 15 are positioned abutting each
other
and fastening means 40 in the form of a threaded fastener, spot welds, blind
rivet or the
like secure the two central webs 30 together. The pallet 1 can also include a
counter-sunk
3o bore or aperture in the holes 45 for hiding the fastening means 40 below
the plane of the
adjacent surfaces. This will ensure no sharp objects, such as the end of a
bolt, protrude
above the adjacent surface of the deck 5, 10. As best seen in Figure 3, the
elongate bearer
15 can also include a stiffener strip 50 to provide further support to the
bearer 15 when
the pallet 1 is required for heavy loads. The stiffener strip 50 is merely
attached along the
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central web 30 at the holes 45 for the fastening means 40. The pallet 1 can
also include
many additional components to provide a more profiled pallet 1. For example,
the top or
bottom decks 5, 10 can include profiled configurations such as corrugations as
best seen
in Figures 2 and 7a, 7b. Cover plates and end caps 55 or the like as seen in
Figures 3 and
4 could also be utilised.
Referring specifically to Figures 1, 5a to 5c and 8, the top and bottom webs
20,
25 are load support flanges providing an opening 47 therebetween allowing
access for
spot welding or attaching threaded fasteners such as screws or bolts or the
like. The
separator of the portions 16, 17 also allows for only one side of the bearer
15 to be
replaced if required. In a preferred form, the webs 20, 25 are abutting. A
rounded non-
sharp edge is preferably provided between the webs 20, 25 and inclined
portions 35. The
overall dimensions of all components can change depending upon the required
pallet 1.
In Figure 2 a standard 1000 x 1200 cm pallet 1 is shown. The pallet 1
dimensions can vary to suit particular industry requirements such as, 1165 x
1165 cm, for
example. The decks 5, 10 can be in varying configurations, such as
corrugations, flat
panels, curves or the like. The corrugations for example, can be in any
direction, non-
uniform, and/or a combination of directions or shapes depending on the load to
be lifted
and moved. In the embodiment shown, galvanised steel corrugations are shown
providing superior strength and durability. The corrugations also provide
maximum
surface contact while retaining structural adequacy. However, a 100% flat
surface 79 can
be provided in place of the corrugations or affixed to the top of the
corrugations (see
Figure 4) or a combination of surfaces can be provided.
The advantages of the pallet 1 as shown herein is that all components can be
disassembled and reassembled or damaged components easily replaced, if
required.
Shaped sleeves 60 (as best seen in Figure 4) made of any material could also
be added to
cover edges and increase strength. End caps 55 could also be added to provide
a more
aesthetically looking pallet 1, provide impact resistance, cover apertures and
edges at the
ends of the bearers 15. If corrugations are used an edge strip 65 could also
be provided to
seal in any openings for hygiene requirements. There is also shown in Figures
2, 6a to 6c,
7a and 7b, openings 75 for the tines or wheels of forklifts and pallet trucks.
The pallet 1
could also include a cross member (not shown) between the bearers 15 or inside
the
corrugations to provide additional support for very heavy loads.
Figure 4 also shows additional componentary including a lip 77 formed in the
corrugations to ensure no sharp edges and to stiffen against impact from a
forklift. A
separate U-shaped cover 60 could also be provided as mentioned above. The lip
77 also
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provides an increase in the horizontal strength of the pallet 1. This
embodiment also
shows a further sheet material 79 across the top of the corrugations and a
stiffener strip
50. The sheet material 79 could be galvanised steel, timber, plastic or any
other material,
if required.
5 Figures 5a to 5d and 8 show different embodiments of the bearer 15. These
embodiments are utilised for different fastener combinations allowing easy
access to the
bearer 15. As seen in Figures 5a and 5b additional members 80 can be included
to
receive the decks 5, 10.
Figures 6a to 6c, 7a and 7b show further embodiments of the invention,
detailing
openings 75 in the pallet 1 for allowing four way entry for a lifting device.
Figure 8, shows a further embodiment of the invention having fastening means
40 in the form of a screw and rivet. The webs 20 and 25 are turned inward to
reduce
sharp edges.
The pallet 1 disclosed herein can be completely disassembled as all components
can be replaced individually quickly and inexpensively. Pallet 1 has extremely
strong
load bearing capacity due to the angles of the members making up the portions
16, 17; has
structural adequacy and load distribution for rotational movements; the shape
can be
altered in all dimensions and angles for various purposes; smooth non sharp
surfaces on
each bearer 15 horizontal side surfaces; small cross sectional area of end
maximises width
of openings 75 for fork lift tines; allows for bolted, riveted, screwed or
welded fixings 40
for joins and decks 5, 10 to bearers 15; holes or apertures 45 are recessed
allowing for
non protruding fixings/connections; external side has no visible joins,
resists dirt
collection; interior space is minimised to reduce contamination area; interior
space small
to enhance any cleaning pressure hose effect; the bearers 15 could be
galvanised steel or
aluminium.
The deck 5, 10 and the additional sheet material layer 79 could be steel,
timber,
plastic, paperboard, composites or fibres. The steel bearers 15 for example
could support
timber decking and be secured by a threaded nail, bolt or the like. The bearer
15 shape
allows for mid height horizontal stiffener 50 attachment for extra heavy
loads; bearer
shape can be segmented to allow for 4 way pallet option; deck 5, 10 can be
adapted to
100% coverage if pallet 1 purpose requires; one or more additional decks 5, 10
could be
added; allows hygienic adaptability for food industry requirements; deck board
profile
can have edge returns 77 roll formed to avoid sharp edges; deck board edge
return 60 to
stiffen end against fork lift and pallet truck impact; bearer 15 shape allows
for timber
deck boards if necessary; deck board shape can have steel strip attached to
cover cavities;
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deck board profile can have 45-60 degree folded ends to eliminate sharp edges;
and
alternatively deck boards can have horizontal angle cover attachment.
Although the invention has been described with reference to specific examples,
it
will be appreciated by those skilled in the art that the invention may be
embodied in many
other forms and other structures.
