Note: Descriptions are shown in the official language in which they were submitted.
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PALLET THAT CAN BE ASSEMBLED WITH SLIDING BOARDS AND A LOCKING
SPINE MEMBER
This invention relates to a pallet and to a method of assembly of a pallet.
Pallets in
accordance with this invention are particularly, but not exclusively, of the
kind used for
transportation and storage of bulky objects, for example, transportation using
fork-lift truck,
trains, hoists or jacks. Pallets in accordance with this invention may also be
used to provide
support surfaces for displays, for example, signs or posters.
Conventional pallets comprise ground or floor engaging bottom deck boards
which may
extend in a first direction, e.g. laterally, of the pallet; stringers or
blocks mounted on the
bottom deck boards and extending in a second direction, e.g. longitudinally of
the pallet to
join the deck boards; and top deck boards mounted on the stringers or blocks
and adapted to
carry a load in use. The top deck boards usually extend parallel to the bottom
deck boards.
Apertures between the top and bottom deck boards are adapted to receive the
tines of a
forklift nr other lifting device or r.pps which may be ntin,hpd toacrane or
hoist.
Conventional pallets are manufactured from timber joists and planks. Wooden
pallets
are difficult and uneconomical to repair and are usually destroyed if damaged
in use. Such
pallets are also bulky and difficult to transport. Nails used to fix the
boards can be a safety
hazard agent to the person handling the pallet or may damage the packaging of
the goods
being transported.
It is an object of the present invention to provide a demountable pallet which
may be
assembled from modular or replaceable components and which can be dismantled
for
transportation, storage or replacement of a damaged component without use of
nails.
According to a first aspect of the present invention, a pallet comprises:
a plurality of side rails, each side rail including upper and lower runners;
a multiplicity of boards, each board being adapted to extend between a runner
of two of
the rails;
one or more spine members extending parallel to the rails, each spine member
including
upper and lower spine runners;
each board including a spine engaging portion adapted for gliding engagement
with n
spine runner; and
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locking means adapted when locked to prevent sliding disengagement of the
boards
from the spine runner;
each board having two ends, the ends being formed with an engagement portion;
each rail having a plurality of sockets, each socket being adapted to receive
and engage
an engagement portion of a respective board;
wherein the board is disengaged from the rail and may be moved parallel to the
rail
between an unlocked position wherein a board may be inserted into or removed
from the
socket and a locked position wherein board is engaged with the rail preventing
removal from
the socket.
The present invention provides a pallet which may be assembled by inserting
the ends
of each board with respective sockets and sliding each board in a direction
parallel to the rails
into engagement with the side rails. Then the spine member may be slidably
engaged with
the boards to form a rigid pallet capable of supporting a load in use. The
pallet is further
capable of being dismantled for transportation, storage or repair. Reduced
volumes are
required for transportation of the disassembled pallet components Service
inspection of the
disassembled products and repair if necessary are facilitated. Different
components of the
pallet may be made from different materials in order to more efficiently meet
their different
structural and load bearing requirements. This allows flexibility of supply
chain
management and product life cycle management. One or more of the components,
preferably
the final locking member, may include an identification device, for example a
radio
frequency identification device (RFID) disc or label so that the pallet has a
recorded identity
from the production date. The physical location may be also recorded and
tracked together
with the servicing record, using GPRS logistics.
Locking or unlocking by movement of the boards parallel to the rails in a
longitudinal
direction with respect to the rails and spine member has the advantage that
the components in
the pallet cannot be disengaged by lateral movements, perpendicular to the
rails during use.
Furthermore prevention of sliding movement of the boards along the spine
member by the
locking means provides a simple and reliable procedure for assembly and for
dismantling the
pallet by placing the rails in position and subsequently adding and removing
the remaining
components. Use of both longitudinal and transverse movements during assembly
is thereby
avoided.
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In a preferred embodiment wherein each board has a tongue at each end, the
tongues
extending transversely of the pallet towards the sockets in the respective
rails; each tongue
including a formation defining an abutment extending parallel to the rail and
adapted to
engage a complementary formation of the rail as the board slides from the
unlocked to the
locked position.
The formation preferably comprises a slot extending parallel to the rail and
dimensioned
to receive a rib integral with the rail and extending towards the socket. The
rib is preferably
a parallel sided part of the box section of the rail.
Alternatively the formation may comprise a rib or series of projections
arranged to be
received in a slot in the rail.
Each board may have a projecting tongue or rib adapted to be slidably received
and
engaged within the channel. Each side rail may include a plurality of inwardly
extending
projections and sockets located between adjacent projections, each socket
being adapted to
receive a board inserted between the rails and further adapted so that the
board when
received in the socket may be moved slidably in a direction parallel to the
rail into the
channels to engage the rails at each end of the board.
The board may have a longitudinal slot extending longitudinally of the pallet,
parallel to
the rail, and adapted to engage an edge of the respective runner. Such an
arrangement
conveniently locks the board and rails together, and is resistant to lateral
or transverse
movement of the rails and boards.
In preferred embodiments the slots or other formations of the boards extend in
use
parallel to the rails in a direction outwardly from the centre of the rail
towards the front or
rear ends of the rail. In these embodiments the boards may be inserted into
sockets and
slidably moved in outward directions into their locked positions.
Each tongue is preferably received by sliding movement within a channel of the
rail.
This serves to facilitate engagement of the board and rail and prevents
twisting in use.
A pallet in accordance with this invention has an advantage that the rails and
spine
member may be formed from hollow box or tubular sections so that the rails and
spine
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members have apertures which extend lengthwise of the pallet. Adjacent pallets
may be
fastened together end-to-end, using rope or chains to form an elongate
structure. Such a
structure may be used as a bridge in the event of flooding or to allow passage
over muddy or
unstable terrain. In preferred embodiments the pallets are composed of
reinforced composite
material, for example a wood reinforced polymeric composite. Such pallets are
buoyant and
may serve as safety floats or may be connected together to form a floating
bridge or pontoon
in the event of flooding or heavy rains.
Pallets in accordance with this invention find applications as support
surfaces for
displays, for example, signs or posters, display light boxes, flooring,
partitions, bed frames,
table tops and benches.
A pallet in accordance with this invention has the further advantage that it
may be
assembled without use of nails, screws, clips or other fixings, avoiding the
need to maintain
and transport a supply of the necessary number of such fixings.
The pallet may be manufactured from extruded polymeric materials, e.g.
polypropylene
or other engineering thermoplastics, or from aluminium or other extrudable
metals. Use of
wood-plastics composite materials is especially preferred. Such materials can
incorporate
scrap timber and wood products. Use of recycled waste wood products is
particularly
preferred in order to minimise environmental damage.
In a preferred embodiment each spine runner includes a pair of longitudinally
extending
ribs, the ribs defining a channel between the ribs, the channel and ribs being
adapted to engage
and retain a complementary formation of the spine engagement portion of a
board.
In an alternative embodiment the spine has a longitudinal axis and spine
runners extending
axially of the spine, and one or more said locking members being axially
rotatable about the
axis;
the locking members including spine runner portions;
the locking members being moveable from an unlocked position wherein the spine
runner portion is aligned with a spine runner to form a continuous runner, and
a locked
position wherein the locking member obstructs the spine runner so that a board
may not be
slidably disengaged from the runner.
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Each rotatable locking member may comprise a single longitudinal rib, the rib
being
adapted to be aligned in the unlocked position with one of the pair of ribs of
a spine runner.
In a preferred embodiment, the locking member comprises two single ribs
located in
diametrically opposed relation on opposite sides of the member. Such an
arrangement allows
the locking member to be disengaged from the board by a single rotational
movement but yet
allows insertion or removal of the board from engagement with the spine.
Preferably, the spine and locking members have an axial bore, a shaft being
received in
the bore to support the locking members during rotation in relation to the
spine. In a first
preferred embodiment, the shaft may be removed from the spine when not in use.
In an
alternative embodiment, the shaft may be permanently located within the bore
to strengthen
the spine and rotatable locking members.
A transverse aperture, lug, socket or other engagement structure may be
provided on the
locking members to receive a bar or tool to facilitate rotation of the member
in use. For
example, an aperture may be adapted to receive the blade of a screwdriver.
In a preferred first embodiment, the side rails have abutments at the ends
thereof. These
serve to prevent boards from sliding off the ends of the rails in use.
In a preferred embodiment, two locking members are provided between two spine
members. The locking members may be located centrally of the spine members and
centrally
of the pallet to define a recess or socket into which boards may be inserted
when the locking
members are in the unlocked position. Following insertion the boards may be
caused to slide
longitudinally onto the spine and into engagement with the side rails.
In preferred embodiments, the side rail may comprise a box section extrusion
with
upper and lower runners facing inwardly of the pallet, each runner comprising
an array of
sections wherein a channel extends along each section with a rebate between
adjacent
channels, the rebate having a dimension to form a socket to receive and engage
an end of a
respective board.
According to a preferred embodiment of this invention, the boards are adapted
to
slidably engage the spine runner from a first end thereof, the locking means
being adapted to
secure at least one board slidably engaged on the first end of the spine.
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Preferably the locking means comprises a bolt which may be received in
apertures in the last
board and in the spine. A bolt may be secured by means of one or more nuts.
This provides
a simple and sturdy means of locking the pallet assembly. Alternatively a
screw or spring
clip arrangement may be used. In addition the locking means may include a
Radio
Frequency Identification Device (RFID) or label to enable identification and
tracking of the
pallet
The spine member may comprise two or more sections adapted to be located end
to end
along the axis of the pallet.
The boards may be separated by spacer sections with relatively narrow width,
each spacer
section being located between a pair of adjacent boards to provide a slatted
upper and/or
lower deck configuration.
The invention is -further described by means of example, but not in any 1
imitntive sense,
with reference to the accompanying drawings, of which:
Figure 1 is a perspective view of a pallet in accordance with the invention;
Figure 2 is a plan view elevation cross sections of a further pallet;
Figures 3 to 8 are perspective views showing assembly of a pallet as shown in
Figure 1;
Figure 9 is a cut away perspective view of a second embodiment of the
invention;
Figure 10 is a view along the cross section of the embodiment shown in Figure
9;
Figures 11 to 18 show further cross sectional and elevation views
corresponding to
Figures 9 and 10;
Figure 19 is a detailed view showing the locking arrangement;
Figure 20 is a cross sectional view illustrating the locking arrangement and
engagement
of the spine and board members; and
Figures 21 to 23 illustrate the board members of the pallet;
Figures 24 to 27 illustrate further embodiments of the invention;
Figure 28 illustrates the spine member of a further embodiment of the
invention; and
Figure 29 illustrates an alternative locking arrangement.
In the following drawings the same reference numerals are used to denote the
like
components in each Figure.
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The pallet shown in Figure 1 comprises a pair of longitudinally extending side
rails or
stringers (1,2) with an array of top deck boards extending between the side
rails. The top
deck boards comprise first (3) and second (4) boards arranged alternately.
Two spine members (6) extend axially longitudinally of the pallet as described
below.
The spine members (6) have axial bores (7) providing a continuous channel from
the front to
the back of the pallet.
An array of lower deck boards (10) similar to the upper deck boards is adapted
to
engage the ground or floor surface in use.
Figure 2 comprises a plan view, side and end elevations, cross section on R-R
and detailed
views of the cross section.
Each side rail (1,2) has a generally box-shaped extruded construction
comprising a
around engaging lower portion (20), upper load supporting portion (21), an
miter skin (72)
and inner skin (23). The inner surface includes upper (24) and lower (25)
runners extending
longitudinally of the pallet. The runners face inwardly of the pallet in use.
Each runner
comprises a channel (26) adapted to receive and engage a correspondingly
shaped projecting
tongue or rib of a board when the pallet is assembled.
The channels (26) are each defined by parallel projections (27) extending
inwardly from
the lower or upper surfaces (20) of the side rail. Rectangular or otherwise
shaped rebates or
sockets (28) are located between each projection (27). The rebate or sockets
(28) are
dimensioned to receive the end of a board during assembly of the pallet.
Figure 3 shows a perspective view of two spine members (6) with lower boards
(10)
attached. A pair of central spine members (30) carry a pair of upwardly
extending parallel
ribs (31,32) defining a channel (33) between the ribs (31,32). A corresponding
pair of lower
ribs (34,38) is provided on the lower surface of the spine. The channel (33)
has a narrow
mouth and wider interior as shown in Figure 20, so that a correspondingly
shaped projection
extending from a board may be inserted into the channel by sliding
longitudinally. The board
is held securely and supported against any twisting movement. Alternatively,
the outer
lateral surfaces of the ribs may be wider at the ends remote from the spine to
engage the
board in use.
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During assembly of the pallet the boards (10) and spacer (4) are slid into
engagement
onto the lower ribs (34,38) of the spine to form two sub assemblies.
Figure 4 shows the next stage of assembly in which upper boards (3) are
slidably
inserted onto the upper ribs (31, 32) of the spine. Slots (40) are arranged to
extend parallel to
the spine outwardly from the centre towards the front or rear of the pallet as
shown in Figure
4.
Figure 5 shows the next stage of assembly in which spacer boards (4) are
inserted
adjacent the upper boards (3). The upper boards (3) have outwardly extending
tongues (41)
for engagement within channels of the rails.
In Figure 6 further boards (3) are inserted onto spines to complete the sub
assemblies of
the pallet.
In Figure 7 the side rails are inserted onto the ends of the sub assemblies so
that the
tongues of the boards are received in the sockets (28). The sub assemblies are
securely
engaged by sliding them outwardly towards the ends of the rails to produce an
assembled
structure as shown in Figure 8. The upper and lower boards are locked into
engagement with
the rails to form a rigid structure. Continuous passageways extend lengthwise
of the pallet
through the rails and spine members so that ropes, cords or chains may be used
to bind two
or more pallets together in the event of flooding or other natural disaster.
The structure and assembly of further embodiments of the invention are
described with
reference to Figures 9 to 20.
In the embodiment shown in Figures 9 and 10 the side rails (50) have a
generally box
shape construction. The inner surface of each side rail has upper and lower
runners
extending longitudinally of the pallet. Each runner includes a channel formed
by parallel
projections (53,54) adapted to receive a correspondingly shaped tongue or
other projection of
the boards (51) when the pallet is assembled. The channels (52) are each
defined by
projections (55) extending inwardly from the upper and lower surfaces of the
side rail.
Rectangular rebates (56) are located between each projection (55). The rebates
or sockets
(56) are dimensioned to receive a board (51) during assembly of the pallet.
During assembly
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the boards (51) are located in the spacers and are then inserted by sliding
into engagement
with the spine (57). A spacer (58) is inserted into sliding engagement with
the spine between
each board (51). In this way a slatted construction is provided.
The spine (57) comprises two portions (59, 60) which collectively have a
length shorter
than the length of the pallet. During assembly of the pallet each spine
portion may be
assembled with upper and lower pairs of two boards (51) to form a H-shaped sub-
unit as
shown in Figures 3 to 6. This sub-units may be inserted into the side rails
(50) following
which the sub units are slid outwardly to engage the boards (51) into the
sockets in the side
rails as shown in Figures 17 and 18. This leaves a central aperture between
the two spine
members. In order to complete the assembly, one of the spine members (60) is
pushed along
the channel formed by the boards so that it contacts the second spine member
to form a
continuous spine. A locking spine member (61) comprising a short spine portion
with a
fixing means such as a socket for a bolt at one end, is then inserted into the
channel end
socket previously occupied by the first spine member to complete the spine
unit. Finally one
or more bolts (62) is located in the aperture (64) to secure the last hoard
(63) to the spine
member (61) as shown in Figure 18.
Figure 20 is an enlarged view of the embodiment shown in Figure 2. This shows
the
spine 6 having upper and lower pairs of parallel ribs (31,34) received in
sockets in the upper
and lower boards (4, 10) and secured by bolts (62).
Figure 21 contains a plan view and elevation of an end board in accordance
with this
embodiment of the invention. The board (117) contains an axial socket (118)
extending
across the width of the board. The socket has a mouth narrower than the base
so as to
slidably receive and engage the runners (112) of the spine member in use.
Slots (119) in the
end portions (120) permit engagement with the projections (108) of the side
rails in use. The
axial opening of the central slot (118) faces in an opposite direction to the
axially extending
openings of the two slots (119). The end of the board (120) has a tongue (121)
adapted to be
received within the socket of the side rail in use.
Figure 22 contains upper and lower plan views, elevations and cross sectional
views of
an altemative end board (122) for insertion onto the spine to complete
assembly of the pallet.
The board contains an axial slot (123) defining a socket for receipt onto the
spine runner.
The socket extends partially across the board including an abutment (127) to
prevent sliding
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of the spine from the hinge (125) at the ends of the boards. Slots (124) are
located adjacent
the ends of the board to permit engagement with the side rails as previously
described. An
aperture (126) is adapted to receive a bolt (not shown) to secure the board to
the spine
member.
Figure 23 shows a board member (128) having a tongue (131) with a slot (130)
extending perpendicular to the board, parallel to the rail and outwardly
towards the end of the
pallet in use. A channel (129) extends across the width of the board (128)
allowing the board
to be slidably engaged on the runner of a spine member as shown in Figure 20.
Figures 24 to 28 illustrate further embodiments of the invention.
Figure 24 shows the first stage of assembly of an embodiment in which lower
boards
(200) are received onto the lower spine runners of spine portions (201,202). A
locking spine
portion (203) having an aperture (204) to receive a bolt is engaged in the end
board. As with
the previously described embodiment the spine members (201,202, 203) provide
continuous
spine runners (205) comprising upwardly and downwardly pairs of ribs
(206,207).
Protective spacers (208, 209) are inserted onto the lower spine runners
between the
boards (200). The protective spacers provide a load bearing, smooth surface
which is
generally co-planer with the lower ground engaging surfaces of the boards
(200). In this way
damage to the spine runners and occlusion of dirt are avoided.
In Figure 25 the above boards (210) have been inserted onto the upper spine
runners
(206,207) the upper boards (210) have tongues (214) with outwardly opening
slots (213)
extending parallel to the spine members as described with reference to the
previous
embodiments. Spacer boards (212) not having the slots (213) are located
between pairs of
boards (210). The end boards (219) may have a blind slot (213) as shown in
Figure 22 to
receive and engage the end of the spine member.
Figure 26 is a view from below the assembled pallet. In Figure 26 rails
(215,216),
lower end boards (218) and protective spacers (208,209,217) form a continuous
planar
ground engaging surface for the pallet.
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Figure 27 illustrates an alternative segmented board in which two half
portions
(220,221) have interlocking central portions (222, 223) with hooked ends (224)
for
engagement on the spine runners. A locking sleeve (225) is inserted into the
spine to retain
the half portions in position after assembly.
Use of the segmented boards is advantageous in facilitating a final step of
assembly of
the pallet. The half board portion may be inserted into a central space
remaining between the
two H-shaped upper board arrays after the boards have been slid outwardly into
their locked
positions on the rails. In alternative embodiments and modes of assembly the
use of
segmented boards is not necessary.
Figure 28 shows an alternative locking member in accordance with this
invention. A
central portion of the spine (300) includes a rotatable locking portion (301).
The locking
portion may be mounted on a shaft or bearing to facilitate rotation axially of
the shaft while
maintaining a continuous axial cavity (302) through which a rope or other
fixing may be
passed in use. The spine member (300) carries an upwardly extending pair of
parallel ribs
(303) and a pair of parallel downwardly extending ribs (304) defining a
channel (305,306)
between each pair of ribs as described with reference to the previous
embodiments. The
locking member (301) has a single upwardly extending rib or projection (306)
and a single
diametrically opposed downwardly facing projection (307). These may be twisted
from a
first position in which they are aligned parallel to the upper and lower ribs
(303,304) to form
a continuous surface upon which a board may slide during assembly or
dismantling of the
pallet, or a second locked position in which the ribs (306,307) are
perpendicular so that
movement of the board along the spine is prevented.
Rotation of locking member may be achieved by inserting a screwdriver or other
elongate tool into an aperture (308) to allow twisting of the locking member
between the
locked and unlocked positions.
Figure 29 illustrates an alternative locking arrangement wherein a spring clip
is used to
secure the end board to the spine member. Any convenient arrangement of spring
clip may
be employed to secure the board to the spine but permitting release of the
board if the pallet
is to be dismantled. In this embodiment the clip has flanges extending in
opposite directions
on the ends to co-operate with complementary formulations on the end of the
spine and
underside of the board.
