Note: Descriptions are shown in the official language in which they were submitted.
WO 2012/012367 CA 02804997 2013-01-09PCT/US2011/044438
Attorney Docket #37665-7
METALLIC PALLET WITH FRAME AND PANEL SUPPORT SURFACE
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Provisional Patent Application No.
61/365,410 filed
July 19, 2010, the entire disclosure of which is hereby incorporated by
reference and relied upon.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates generally to horizontally supported planar
surfaces such as
industrial platforms having a support surface provided with supporting means
whereby a load
may be supported relatively close to a floor and having means to receive
handling means beneath
said surface or load and wherein the support surfaces are made of metal.
Related Art
[0003] Pallets are commonly used to support and transport bundled objects or
loads in
application like that shown in Figure 1. Traditionally, pallets have been
constructed from wood
members assembled together. However, wooden pallets are subject to many
drawbacks,
including a relatively short lifespan, chemical contamination, insect
infestation, and fire hazard,
to name a few. More recently, pallets have been constructed from plastic
materials which can be
more durable than wood and are typically insect resistant, however are still
subject to chemical
contamination, fire hazards and other shortcomings. While additives can be
used to make a
plastic pallet more fire retardant, such additives are costly and generally
disfavored in situations
where food handling is required. There is a desire within the material
handling industry to
identify new materials suitable for manufacturing cargo carrying pallets which
will provide
superior functionality at a cost competitive price with other options.
[0004] Some examples of pallet constructions representative of prior art
teachings may be
found in US Patent No. 6,622,642 to Ohaneisan granted September 23, 2003, US
2006/0254478
to Kruger et al. published November 16, 2006, and US 2006/0201400 to Moore,
Jr. et al.
published September 14, 2006. These examples of prior art illustrate various
approaches in
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mixed forms of construction which include at least some metallic components.
In these
examples, the pallets include a top deck or load engaging surface which may be
composed of a
single large integral panel or such a panel variously attached to a
surrounding frame made from
plastic or wood.
[0005] One drawback found in prior art constructions relates to the general
lack of strength of
the pallet in terms of resisting racking forces. Racking forces are generated
when a pallet
experiences an impact force to one of its corners. This may occur when the
pallet is being
transported by a forklift, or when the pallet is stationary but some object
collides with it. It will
be appreciated that metallic pallets are substantially more expensive to
manufacture than wooden
pallets. The cost proposition for a metallic pallet therefore becomes
favorable when the metallic
pallet can operate in specialized settings (e.g., in food handling and other
operations requiring
sterilization) and/or the metallic pallet can enjoy a substantially longer
service life than the
typical wooden pallet or other available alternatives. Accordingly, with
regard to the latter
consideration, constructing a metallic pallet that has the ability to
withstand racking forces,
rough handling and other stressful conditions is advantageous to the business
proposition for this
class of products.
[0006] With regard to the construction cost of a metallic pallet, there are
two significant
contributing factors: material cost and fabrication cost. Of these,
fabrication costs are largely a
controllable factor. Prior art pallet assemblies may include numerous
components that must be
assembled together with fasteners or welding at many intersection points
resulting in relatively
high cost and effort. As a result, the fabrication costs for a metallic pallet
assembly may
substantially overshadow the material costs. Accordingly, metallic pallets
have inherent benefits
and are being increasingly accepted within an industry accustomed to utilizing
cheap wooden
pallets. Nevertheless, there remains opportunity to further improve pallet
designs and
constructions with the objectives to reduce construction cost and to extend
service life.
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SUMMARY OF THE INVENTION
[0007] A metallic pallet is provided of the type for supporting objects for
storage and transport.
The pallet comprises a generally planar top side having a substantially
rectangular configuration
defining four corners. The top side includes four elongated outer top frame
members. The top
side also includes a first inner top frame member and a second inner top frame
member. The
outer and inner top frame members are arranged to form four bounded interior
fields. A
generally planar bottom side is provided having a substantially rectangular
configuration
defining four corners. The bottom side includes four elongated outer bottom
frame members.
The bottom side is disposed below the top side so that its corners are
vertically aligned with the
corners of the top side in corresponding pairs. Likewise, the outer top and
outer bottom frame
members are arranged in opposing pairs. Four generally hollow corner pieces
are provided.
Each corner piece extends between a respective aligned pair of corners of the
top and bottom
sides. The top side further includes a rigid, unitary corner panel fixedly
disposed in each of the
four bounded interior fields.
[0008] The subject invention is distinguished from prior art pallet designs by
providing a top
side configured in a frame-and-panel type construction wherein four rigid,
unitary quarter panel
pieces are set within and fixed to the frame members. This design, which
represents a departure
from prior art techniques, enables a metallic pallet assembly to be fabricated
much more quickly
and with less effort than required by prior art designs. Furthermore, the
unique design
substantially increases the ability of a metallic pallet to resist racking and
other undesirable
impact forces, which thereby favorably extends the service life and hence cost
benefit of a
metallic pallet.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other features and advantages of the present invention will
become more
readily appreciated when considered in connection with the following detailed
description and
appended drawings, wherein:
[0010] Figure 1 is an environmental view showing a pallet constructed in
accordance with one
embodiment of this invention utilized to support cargo and poised for handling
via a common
forklift vehicle;
[0011] Figure 2 is a perspective view of the subject pallet;
[0012] Figure 3 is a top view of the subject pallet;
[0013] Figure 4 is a cross-sectional view taken generally along lines 4-4 in
Figure 2;
[0014] Figure 5 is a perspective view showing the bottom or underside of the
pallet according
to Figure 2;
[0015] Figure 6 is an exploded view of the pallet shown in Figure 2;
[0016] Figure 7 is an exploded view of a corner piece according to an
embodiment of this
invention;
[0017] Figure 8 is a perspective view of an exterior spacer block according to
an embodiment
of this invention;
[0018] Figure 9 is a schematic view describing tracking capabilities for the
subject pallet when
configured to include an RFID tag;
[0019] Figure 10 is a perspective view of a first alternative corner piece
construction;
[0020] Figure 11 is an exploded view of the alternative comer piece shown in
Figure 10;
[0021] Figure 12 is a cross-sectional view taken generally along lines 12-12
in Figure 10:
[0022] Figure 13 is a perspective view of a separately formed cover used in
conjunction with
the first alternative corner piece shown in Figure 10;
[0023] Figure 14 is a fragmentary perspective view showing a second
alternative corner piece
in partially exploded fashion and illustrating the optional inclusion of an
RFID tag in the hollow
space therein; and
[0024] Figure 15 is a perspective view of a third alternative corner piece
design.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring to the figures, wherein like numerals indicate like or
corresponding parts
throughout the several views, a pallet constructed in accordance with
embodiments of this
invention is generally shown at 20. Standard pallet dimensions are given as 48
inches x 40
inches x .6 inches, however the specific dimensional properties of the pallet
20 are subject to
alteration depending upon the application.
[0026] As perhaps best shown in Figures 2-6, the pallet 20 includes a
generally planar top side,
generally indicated at 22. The top side 22 establishes a generally horizontal
surface for
supporting objects such as cargo for storage and transport. The top side 22 is
elevated above the
floor or other under supporting structure so that the tines of a forklift 24
(Figure 1) can be
inserted under the top side 22 in the customary fashion. The top side 22 is a
substantially
rectangular configuration as suggested by the dimensions suggested above,
however this is also
subject to variation depending upon design choice. The top side 22 defines
four corners which,
in the preferred embodiment, are represented by notches 26. The top side 22
also includes four
elongated outer top frame members comprised of two long rails 28 and two short
rails 30. The
long 28 and short 30 rails are arranged about the perimeter of the top side 22
and extend each
into the notches 26 thus establishing a generally rectangular shape for the
top side 22. The long
28 and short 30 rails are preferably made from extruded aluminum having any
desirable and
suitable cross-sectional shape such as, for example, shown in the cross-
section of Figure 4. The
top side 22 further includes a first inner top frame member 32 and a second
inner top frame
member 34. The first inner top frame member 32 is affixed parallel to and
halfway between the
long rails 28, whereas the second inner top frame member 34 is disposed
parallel to and midway
between the short rails 30. The second inner top frame member 34
perpendicularly bisects the
first inner top frame member 32 at a top inner section joint 36, thus
establishing a somewhat
cruciform construction inset within the perimeter of rails 28, 30. The rails
28, 30 and inner top
frame members 32, 34 are all disposed within a common plane, generally, which
forms the
horizontal support surface of the top side 22. In this arrangement, four
bounded interior top
fields 38 are formed. The four bounded interior fields 38 are the openings
created by the
surrounding frame members 28, 30, 32, 34, are generally equal in size and
generally proportional
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to the overall rectangular configuration of the top side 22, as perhaps best
shown in Figure 2.
Preferably, the inner top frame members 32, 34 are affixed such as by welding
to one another at
the top inner section joint 36 as well as at their terminal ends to the
respective long 28 and short
30 rails, thereby providing a rigid matrix and generally fixing the shape of
the bounded interior
fields 38.
[0027] Turning now to Figure 5, the pallet 20 is shown including a generally
planar bottom
side 40. The bottom side 40, like the top side 22, also has a substantially
rectangular
configuration having corners defined by notches 42. The outer dimensional
properties of the
bottom side 40 are substantially identical to that of the top side 22 so that
the notches 26, 42 can
be directly aligned one over the other. The bottom side 40 also includes four
elongated outer
frame members comprised of long 44 and short 46 rails. The short rails 46 of
the bottom side 40
are generally congruent with the short rails 30 of the top side 22, and
likewise the long rails 44 of
the bottom side are generally congruent with the long rails 28 of the top side
22. unlike the rails
28, 30 of the top side 22, however, in the preferred embodiment shown in
Figures 4 and 5, the
rails 44, 46 of the bottom side 40 are significantly wider (measured
laterally) than their long 28
and short 30 rail counterparts of the top side 22. As a result, the long 44
and short 46 rails of the
bottom side 40 may, in one embodiment, directly connect to one another at
their terminal ends
via a truncated miter joint 40. This miter joint 48 may be welded to provide
direct fix connection
between the long 44 and short 46 rails. The bottom side 40 further includes a
first inner bottom
frame member 50 and a second inner bottom frame member 52. The second inner
bottom frame
member 52 perpendicularly bisects the first inner bottom frame member 50 at a
bottom
intersection joint 54 which may be welded to secure the frame members 50, 52
to one another.
Additionally, the terminal ends of each of the first 50 and second 52 inner
bottom frame
members may be attached at their respective ends to the inner edges of the
long 44 and short 46
rails such as by welding to establish a strong matrix or skeletal
construction.
[0028] Four generally identical, hollow corner pieces are generally indicated
at 56. The corner
pieces 56 each extend between a respective aligned pair of corners of the top
22 and bottom 40
sides as represented by their respective notches 26, 42. In other words, the
corner pieces 56 fit
into each of the notches 26, 42 and are there securely attached such as by
welding so as to rigidly
join the top side 22 to the bottom side 40 via the corner pieces 56. Thus,
because the corner
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pieces 56 are set into the notches 26, 42, it may be seen that the corner
pieces 56 each interrupt
the generally planar top 22 and bottom 40 sides such that the top 22 and
bottom 40 sides do not
overlie the corner pieces 56. As a result, corner impacts to the pallet 20 may
be absorbed
entirely by deformation of the hollow corner pieces 56 without distorting the
planar
configurations of the top 22 and bottom 40 sides.
[0029] Various configurations for corner pieces 56 may be found by reference
to the
applicant's co-pending US 2010/0218705, published September 2, 2010, the
entire disclosure of
which is hereby incorporated by reference and relied upon. Figure 7 is an
exploded view of a
corner piece 56 according to one preferred embodiment of the subject invention
which is
designed for optimal performance, low cost, ease of construction, as well as
the ability to safely
contain an RFID tag 58 (Figure 14) or other tracking features. The corner
piece 56 shown here
comprises an extruded aluminum body establishing perpendicular back walls 60
in direct
abutting contact with the top 22 and bottom 40 sides. Upper and lower plates
62, which in this
example are made from stamped aluminum sheet stock, are respectively affixed
to the back walls
60 such as by welding or by other suitable fixation technique. As a result,
the upper plate 62 is
generally planar with the top side 22 and the lower plate 62 is generally
planar with the bottom
side 40 thereby contributing to the load carrying capacity without increasing
or diminishing the
loading stresses. A cover 64 is formed integrally with the back walls 60
during the extrusion
process. The cover 64 is configured to simultaneously engage the back walls 60
and the upper
and lower plates 62 to provide a solid, secure exposed area for the corner
piece 56. The cover 64
includes an outer edge 66 establishing the leading or terminal corner for the
pallet 20. Generous
deformation grooves 68 may be formed in the cover 64 laterally on either side
of the outer edge
66 to provide controlled collapse in the event of impact. The corner pieces 56
may further
include internal webbing 70 formed integrally during the extrusion process to
join the cover 64
and back walls 60 for both strength and controlling deformation. Through this
design, the corner
pieces 56 may absorb and deform under control substantial impact forces
without stressing the
top 22 or bottom 40 sides and thereby helping to maintain their planar nature
for extended
surface life of the pallet 20. The upper and lower plates 62 provide an
enclosed space, i.e.,
hollow, in the corner pieces 56 to resist infiltration by liquids or other
unwanted substances.
Each plate 62 may include a small hole 72 aligned over an intersection point
74 of the webbing
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70. During the assembly process, the plates 62 are positioned over the
extruded body section
with the holes 72 providing a convenient location through which to place a
small tack weld to the
webbing 70 and thereby secure the plates 62 in position.
[0030] As mentioned, a small RFID tag 58 may be sealed inside one or more of
the corner
pieces 56 to provide pallet locating and tracking capabilities. An adhesive
may be used to
anchor and seal the RFID tag 58 inside the corner piece 56. Alternatively, the
RFID tag 58 may
be securely stationed in a pocket or receptacle formed integrally with or
subsequently attached to
the inside of the corner piece 56. In this way, the RFID tag 58 can be
contained in a protected
enclosure so as to provide long term service life and functionality for
purposes of tracking the
pallet 20. If the RFID tag 58 is installed into a comer piece 56 prior to
assembly of that corner
piece 56 with the top 22 and bottom 40 sides, the RFID tag 58 is preferably
retained in a position
spaced as far as possible from each of the back walls 60 where welding occurs
during attachment
to the top 22 and bottom 40 sides. This will help protect the RFID tag 58 from
damage due to
excessive heat that occurs during welding operations. Conversely, the RFID tag
58 is also
located as far as possible from the outer edge 66 where the majority of
deformation is expected
to occur in use. This will help protect the RFID tag 58 from damage for a
longer service life.
[0031] Figure 9 shows an exemplary, highly schematic method by which the RFID
tag 58 may
be used to triangulate the position of a pallet 20 which has been lost or
possibly stolen. Using
known RFID technology, the exact position of a pallet 20 with respect to a
digital map 76 can be
determined. Of course, the map 76 may be specific to a particular warehouse or
manufacturing
facility, or used more generally to track pallets 20 which may be stolen or
misplaced in a much
wider geographic area. Additional functionality may be incorporated into the
RFID tag 58
according to known techniques.
[0032] Returning to Figures 6 and 8, the pallet 20 is shown including a
plurality of extruded
aluminum spacer blocks 78, 80. Each spacer block 78, 80 extends
perpendicularly between the
top 22 and bottom 40 sides for holding the top 22 and bottom 40 sides in
generally parallel
spaced and aligned relation to one another so that the notched corners 26, 42
remain vertically
aligned and so that the corresponding pairs of long 28, 44 and short 30, 46
rails remain aligned.
Furthermore, the spacer blocks 78, 80 increase the weight force loading with
which the pallet 20
is capable of supporting. Each spacer block 78, 80 may include at least one
internal web. Four
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spacer blocks 78 comprise exterior spacer blocks 70 arranged about the outer
periphery of the
pallet 20. Two exterior spacer blocks 78 extend between the respective pairs
of long rails 28, 44,
whereas another two exterior spacer blocks 78 extend between opposing short
rails 30, 46.
These exterior spacer blocks 78 are preferably made from extruded aluminum
materials and
welded in place.
[0033] As perhaps best shown in Figure 8, the exterior spacer blocks 78 have a
generally D-
shaped profile when viewed in cross-section. This D-shaped profile includes an
outer convex
portion 82 that is oriented outwardly from the pallet 20. In other words, as
perhaps best shown
in Figures 2 and 6, the convex portions 82 of the exterior spacer blocks 78
face outwardly and so
that if contacted by the tines of a forklift 24, they will gently direct the
tines to the side usually
with little to no damage. Preferably, although not necessarily, at least one
spacer block 80
comprises an interior spacer block 80 disposed for direct contact between the
backbone 34 and
bottom inner section joint 54 to provide column strength in the center of the
pallet 20. The
interior spacer block 80 may have a generally rectangular profile in cross-
section. Like the
exterior spacer block 78, the interior spacer block 80 is also preferably made
from extruded
aluminum material and securely welded in place at each end
[0034] Referring again to Figures 2-6, the top side 22 is shown including a
rigid, unitary
quarter panel, generally indicated at 84, fixedly disposed in each of the four
bounded top interior
fields 38. The quarter panels 84 are preferably made from aluminum in a die
casting operation.
In one embodiment, the top surfaces of the quarter panels 84 are generally
flush with the top
surfaces of the outer 28, 30 and inner 32, 34 frame members to reduce edges on
the support
surface which might snag cargo. The outer peripheral edges of each quarter
panel 84 are
preferably welded to the directly adjacent outer 28, 30 and inner 32, 34 frame
members. Stitch
welding is a suitable welding technique. The inside edges of the outer 28, 30
and inner 32, 34
frame members may be formed with notch-like rabbets to receive the peripheral
edges of the
quarter panels 84. Rabbets, if used, mechanically strengthen the welded
joints. All interior
edges of each field 38, whether rabbeted or not, are welded directly to the
exterior edges of each
quarter panel 84 thereby substantially strengthening the top side 22 with a
relatively minimal
amount of fabrication effort. By welding the outer edges of each quarter panel
84 to the rails 28,
30 and inner top frame members 32, 34, an integral top side 22 is created
which has the ability to
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resist racking forces and other impacts that would otherwise disfigure the
planar configuration of
the top side 22. As a result, the subject pallet 20 is substantially stronger
than prior art designs
and is considerably easier and faster to fabricate. The relatively long weld
lines provided at the
interface between quarter panels 84 and frame members 28, 30, 32, 34 that
extend in both
longitudinal and lateral directions create a solid yet easily manufactured top
side 22 capable of
extended service life and operation when compared with prior art
constructions.
[0035] Each quarter panel 84 may include at least one, but as shown four hand
grips 86
adjacent the inner top frame members 32, 34. The hand grips 86 are formed
integrally in the
quarter panels 84 near the interior of the pallet 20, making it convenient for
a person to carry the
pallet 20. Each quarter panel 84 may further include a plurality of lightening
holes 88 to reduce
weight and material costs, provide ventilation and multiple drainage paths for
liquids. The
quarter panels 84 may further include a plurality of intersecting reinforcing
ribs 90 to provide
strength and resist deflection.
[0036] Figures 10-13 depict a first alternative design for the corner pieces
156. In this
alternative embodiment, reference numerals previously set forth are reused for
convenience but
offset by 100. As shown, the corner pieces 156 include perpendicular back
walls 160 together
with upper and lower plates 162. However, in this embodiment, the back walls
160 and plates
162 are formed as an integral assembly from aluminum or other suitable
material. Here, the
cover 164 is separately formed from a plastic or hard rubber material. Webbing
170 is not
formed as part of the cover 164, but rather integral with the back walls 160
and plates 162. The
cover 164 includes notches 192 for receiving or engaging with the outer edges
of the webbing
170 which, here, is formed as three vertical ribs. The upper and lower plates
162 are also formed
with chamfers 194. The outer edge 166 of the cover 164 is configured with
short extensions to
directly engage the chamfers 194 as perhaps best shown in Figure 10. Through
this design, the
cover 164 and cast aluminum components become mechanically interlocked so that
the corner
pieces 156 may absorb and partially collapse in response to impact forces
without stressing the
top 22 or bottom 40 sides and thereby helping to maintain their planar nature
for an extended
service life of the pallet 20. The hollow corner pieces 156 resist
infiltration by liquids or other
unwanted substances.
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[0037] Figure 14 shows a second alternative embodiment of the corner piece
256, wherein like
or corresponding parts are indicated with reference numerals offset by 200. In
this example, a
simplified version of the corner piece 256 includes a less sophisticated
separate cover 264 which
may be secured in position to a cast aluminum back wall 260 and upper/lower
plate 262
construction. A single horizontal web 270 and optional intersecting vertical
web may be formed
therein to improve crush resistance. An RFID tag 58 can be placed inside the
hollow corner
piece 256 and secured with a suitable adhesive or by other means as described
previously.
[0038] Figure 15 shows yet another alternative construction for a corner piece
356, with like or
corresponding parts being identified with similar reference numbers offset by
300. In this
example, the corner piece 356 is made from cast aluminum and omits the cover
altogether so as
to present an open cellular hollow corner for the pallet. In all other
respects, the corner piece 356
functions similarly to that described above.
[0039] The foregoing invention has been described in accordance with the
relevant legal
standards, thus the description is exemplary rather than limiting in nature.
Variations and
modifications to the disclosed embodiment may become apparent to those skilled
in the art and
fall within the scope of the invention.
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