Note: Descriptions are shown in the official language in which they were submitted.
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1
MODULAR PALLET
BACKGROUND OF THE INVENTION
[0001] The invention relates generally to devices used in packaging,
storing and
transporting, and more specifically to a modular pallet for packaging, storing
and transporting
items with shapes that inhibit them from being readily stacked.
[0002] It is known in the transporting/shipping industry that an
apparatus should be
used to retain cargo for stability and ease in movement before, during, and
after shipping.
1 0 The generic category for such an apparatus is a "pallet" or a "skid". A
pallet is formed from a
plurality of perpendicular members stacked and attached in such a way to
permit a forklift
(also called a lift truck, a fork truck, or a forklift truck) to lift and
manipulate them. A pallet
is used to elevate one or more objects (herein referred to as "cargo") above a
surface on which
the pallet rests. A forklift has horizontal forks extending from the front of
the forklift that
extend into voids formed under a pallet and its cargo to enable the forklift
to transport the
pallet short distances, such as within a warehouse, dock, semi-trailer or any
other enclosure or
area.
[0003] Cargo is placed on a pallet and commonly secured to the pallet
to prevent
movement of the cargo relative to the pallet during transportation. An example
of cargo that
is commonly stacked on a pallet is parallelepiped boxes. Identical boxes may
be stacked
neatly on the top of a pallet and attached to the pallet by single-use straps
made of plastic or
metal, tacky polymer sheeting commonly referred to as "shrink wrap", or any
other fastener.
Conventional pallets work well for a plurality of identical or even dissimilar
boxes that stack
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well and pack tightly because they tend not to shift during transit. It is
more difficult to attach
spherical, circular cylindrical or oddly-shaped cargo to pallets. For example,
if someone
wishes to ship multiple cylindrical grinding wheels, as shown in Fig. 1, such
wheels are
typically placed with their curved sides between two substantially identical
and parallel slats
of a conventional pallet, and straps are fixed around the cargo. This provides
little resistance
to rolling or other shifting of the heavy grinding wheels relative to the
pallet, and only works
when the space in the pallet can accommodate the cargo.
[0004] There is a need for a pallet that accommodates various sizes of
spherical,
circular cylindrical and oddly-shaped objects, and enables stable attachment
of such objects to
the pallet.
BRIEF SUMMARY OF THE INVENTION
10005] Disclosed herein is an apparatus that is used to retain cargo
for stability and
ease in movement before, during, and after shipping. The generic category for
the apparatus
is referred to as "pallets" or sometimes "skids". A preferred pallet has a
first runner, a second
runner spaced from, and substantial parallel to, the first runner, and
preferably a third runner
spaced from, and substantially parallel to, the first and second runners. A
first slat is
removably mounted to the runners and a second slat is removably mounted to the
runners
with a gap between the first and second slats. The first slat has a first
cargo-supporting face
on a first side and a second cargo-supporting face on an opposite, second
side, and the second
slat has a first cargo-supporting face on a first side and a second cargo-
supporting face on an
opposite, second side.
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[0006] When the slats are mounted to the runners with the slats'
first faces facing one
another, the slats' first faces form a first pair of cargo-receiving surfaces.
When the slats are
mounted to the runners with the slats' second faces facing one another, the
slats' second faces
form a second pair of cargo-receiving surfaces. The first pair of cargo-
receiving surfaces
contacts the cargo differently than the second pair of cargo-receiving
surfaces, such as at
different points, or by contacting different quantities of surface area, or
both.
[0007] In a preferred pallet, the runners have slat grooves formed
therein to receive
contacting portions of the slats. Protective endwalls are preferably formed in
the slat grooves
formed in the end runners, and the endwalls extend over at least a portion of
the first and
second slats' ends. The slat grooves and the endwalls prevent, or reduce the
probability of,
any structure, such as a forklift fork, being inserted between the slats and
the runners. The
pallet preferably comprises removable pins extending through aligned apertures
formed
through the slats and through the slat grooves formed in the runners. The pins
preferably
have a first head at a first end of a narrower shaft and a second head at an
opposite, second
end of the shaft. A slot is formed in the first head that permits the first
head to compress and
expand back to its original position, thereby permitting one end of the pins
to be inserted into
a smaller aperture.
[0008] The apertures formed through the slats and through the slat
grooves formed in
the runners are centrally disposed in the slats and the slat grooves. This
permits the slats to be
positioned in the slat grooves in either of two orientations with the
apertures in the slats
aligned in corresponding apertures in the runners. Such a structural
configuration permits the
slats to be reversed and positioned in the slat grooves in either of two
orientations.
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[0009] In an alternative embodiment, at least one of the slats has a
blocker extending
laterally therefrom to reduce contact between the cargo on the pallet and a
device used to lift
and manipulate the cargo, such as a forklift. By including a blocker on the
slat or slats, a
forklift raising the pallet from one side or the other may not impact the
cargo, but instead
impacts the blocker first. In order to have blockers that extend far enough
laterally, but that
also may be turned inwardly when not in use, the blockers on facing slats may
be interlaced,
such as by having peaks and valleys into which peaks of facing blockers are
inserted.
[0010] Also disclosed herein is a method of constructing a pallet to
support cargo that
has an outer surface. The method comprises taking a pallet comprising first,
second and third
runners and first and second slats mounted thereto, and removing at least the
first slat. The
second runner is spaced from, and substantially parallel to, the first runner,
and the third
runner is spaced from, and substantially parallel to, the first and second
runners. The first
elongated slat is removably mounted to the runners in a first series of
aligned slat grooves
formed in the runners. The first slat has a first cargo-supporting face on a
first side and a
second cargo-supporting face on an opposite, second side. The second elongated
slat is
removably mounted, with a gap between the slats, to the runners in a second
series of aligned
slat grooves formed in the runners. The second slat has a first cargo-
supporting face on a
first side and a second cargo-supporting face on an opposite, second side. The
first cargo-
supporting face of the first slat faces the first cargo-supporting face of the
second slat. The
step of removing includes removing at least the first of the slats from the
runners and
mounting the first of the slats to the runners in the slat grooves with the
second cargo-
supporting face of the first slat facing the second slat. This is a reversal
of the orientation of
at least one of the slats so that the best arrangement of cargo-supporting
faces can be selected.
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Both slats may be reversed, or the best combination of the two cargo-
supporting faces can be
constructed by simply orientating the slats in the best configuration. This
method also
contemplates repair of the pallet.
5
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BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] Fig. 1 is a view in perspective illustrating a prior art pallet
with circular
cylindrical objects resting thereon.
[0012] Fig. 2 is a view in perspective illustrating an embodiment of the
present
invention.
[0013] Fig. 3 is a view in perspective illustrating an end runner
component of the
present invention shown in Fig. 2.
[0014] Fig. 4 is a view in perspective illustrating a middle runner
component of the
present invention shown in Fig. 2.
[0015] Fig. 5 is a view in perspective illustrating a slat component
of the present
invention shown in Fig. 2.
[0016] Fig. 6 is an end view illustrating the slat component of Fig.
5.
[0017] Fig. 7 is a view in perspective illustrating the runner
components of the
embodiment shown in Fig. 2.
[0018] Fig. 8 is a view in perspective illustrating the embodiment of
Fig. 2 in a state
of partial assembly.
[0019] Fig. 9 is a view in perspective illustrating the structures
shown in Fig. 7 with
the pins mounted as they would be in Fig. 8, but with the slat removed for
illustrative
purposes.
[0020] Fig. 10 is a view in perspective illustrating the structures
shown in Fig. 8 with
the pins mounted as they would be in Fig. 11, but with the slat removed for
illustrative
purposes.
[0021] Fig. 11 is a view in perspective illustrating the embodiment of
Fig. 2.
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[0022] Fig. 12 is a top view illustrating the embodiment of Fig. 2.
[0023] Fig. 13 is an end view illustrating an alternative arrangement
of the slats of the
embodiment of Fig. 2.
[0024] Fig. 14 is an end view illustrating another alternative
arrangement of the slats
of the embodiment of Fig. 2.
[0025] Fig. 15 is an end view in perspective illustrating the
embodiment of Fig. 2.
[0026] Fig. 16 is a side view in perspective illustrating the
embodiment of Fig. 15
with one of the end runners omitted, but with the pins shown as they would be
positioned
were the missing runner not omitted.
[0027] Fig. 17 is an end view illustrating the embodiment of Fig. 2 with
cargo
mounted thereto.
[0028] Fig. 18 is a top view illustrating an end runner.
[0029] Fig. 19 is a bottom view illustrating the end runner of Fig.
18.
[0030] Fig. 20 is a view in perspective illustrating the end runner
of Fig. 18.
[0031] Fig. 21 is a bottom view in perspective illustrating the end runner
of Fig. 18.
[0032] Fig. 22 is a bottom view illustrating a slat.
[0033] Fig. 23 is a top view illustrating the slat of Fig. 22.
[0034] Fig. 24 is a side view illustrating the slat of Fig. 22.
[0035] Fig. 25 is an opposite side view illustrating the slat of Fig.
22.
[0036] Fig. 26 is a top view illustrating an end of the slat of Fig. 22.
[0037] Fig. 27 is a view in perspective illustrating the slat of Fig.
22.
[0038] Fig. 28 is a side view illustrating numerous pins used in the
present invention.
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[0039] Fig. 29 is a view in perspective illustrating the present
invention with cargo
mounted thereto.
[0040] Fig. 30 is a bottom magnified view illustrating a pin end.
[0041] Fig. 31 is a view in perspective illustrating an alternative
embodiment of the
invention.
[0042] Fig. 32 is an end view illustrating the embodiment of Fig. 31.
[0043] Fig. 33 is an end view illustrating the embodiment of Fig. 31
with cargo shown
mounted thereto.
[0044] Fig. 34 is a top view illustrating the embodiment of Fig. 31.
[0045] Fig. 35 is a view in perspective illustrating the embodiment of Fig.
31 in an
alternative configuration.
[0046] Fig. 36 is a top view illustrating the embodiment of Fig. 31
in the alternative
configuration shown in Fig. 35.
[0047] In describing the preferred embodiment of the invention which
is illustrated in
the drawings, specific terminology will be resorted to for the sake of
clarity. However, it is
not intended that the invention be limited to the specific term so selected
and it is to be
understood that each specific term includes all technical equivalents which
operate in a
similar manner to accomplish a similar purpose. For example, the word
connected or terms
similar thereto are often used. They are not limited to direct connection, but
include
connection through other elements where such connection is recognized as being
equivalent
by those skilled in the art.
9
DETAILED DESCRIPTION OF THE INVENTION
- [0049] A
modular pallet 10 is shown in Fig. 2 made in accordance with the present
invention. The pallet 10 has two slats 12 and 14 supported by three runners
20, 22, and 24.
An analogous component for a slat in a conventional pallet may be called a
"deckboard", and
an analogous component for a runner in a conventional pallet may be called a
"bearer". The
slats 12 and 14 are substantially perpendicularly mounted to the runners 20-24
in an operable
position, as shown in Fig. 2, and this creates a configuration that may be
useful to receive,
store and transport objects that are not readily stacked. The slats 12 and 14
may not be
exactly perpendicular, but a transverse orientation that is within typical
pallet tolerances is
acceptable.
[0050]
There are multiple pins 30 used in the pallet 10 to attach the slats 12 and 14
to
the runners 20-24. Each pin 30 extends through a bore that has a similar, but
larger,
cylindrical shape to the exterior of the pin 30. Such bores are formed in one
of the slats 12-14
and a similarly-shaped bore is formed in one of the runners 20-24. The
cooperation between
the pins 30 and the structure that defines the bores allows the pins 30 to
attach each of the
slats 12 and 14 to the underlying runners 20-24 where the substantially
perpendicular
components intersect as shown in Fig. 2. The pins 30 are preferably made of
durable plastic,
as are most or all components of the pallet 10, unless stated otherwise.
[0051] As
shown in Fig. 28, the pins 30 preferably have a first head 32 on a shaft 36,
in the manner of a nail, and a second head 34 on an opposite shaft end. The
shaft 36 connects
the two heads 32 and 34. A slot 34s is formed through the head 34, and permits
the two
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spaced fingers formed on opposite sides of the slot 34s to compress inwardly
under a radial
force and expand outwardly upon release of that force.
[0052] Attachment of one of the pins 30 occurs by compressing the
fingers towards
the slot 34s and inserting the compressed head 34 into the exposed aperture of
a bore, which
5 aperture is smaller than either head 32 or 34 (when the head 34 is
expanded). Compression of
the head 34 allows the pin 30 to be inserted through the smaller aperture
until the head 32 is
about to seat against the structure at the end of the bore. The length of the
bore is slightly
shorter than the length of the shaft 36 so that, just before the head 32
seats, the head 34 exits
the opposite end of the bore into which the pin 30 is inserted, and the
fingers expand away
10 from one another. Thus, the head 32 and the slotted head 34 function in
the manner of a nail
or bolt head to prevent removal of the pin 30 without first compressing the
fingers on opposite
sides of the slot 34s.
[0053] An advantage of using the pins 30 on the pallet 10 is that if
one or more
components of the pallet 10 are damaged or need to be separated from one
another for any
reason, one need merely remove the associated pin or pins 30, and the slat
and/or runner may
be readily separated and replaced. Removal of the pins 30 is effected by
simply compressing
the fingers at the head 34 and pushing the pin 30 through the bore in the
direction opposite of
that in which it was inserted until the pin 30 is entirely removed from the
bore. The removed
pin or pins 30 may be re-used due to the fact that compressing the fingers on
the slotted end
34 does not damage or severely wear the pin 30.
[0054] The pallet 10 is made up of at least three types of major
components, which are
shown in Figs. 3, 4 and 5: end runners, middle runners and slats. Of course,
there may be
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more than one of each component on a given pallet, and the pins 30 are used to
connect the
major components together to form the completed pallet.
[0055] The end runner 20 is the first major component, and is shown
in Fig. 3 having
two slat grooves 20a and 20b, each of which has a respective end wall 20c and
20d and
opposing lateral (relative to the orientation of a finished pallet) walls that
adjoin the respective
end walls. The pin apertures 20e and 20f are at the ends of bores that extend
through the end
runner to receive the pins 30, and are centrally located longitudinally of the
end runner 20
within the slat grooves 20a and 20b to permit reversal in the position of the
slats 12 and 14 in
the grooves as described below. Two preferably identical end runners 20 and 24
are used
with the pallet 10, and they are positioned as mirror images of one another on
opposite ends
of the pallet 10 as shown in Fig. 7. With the first end runner 20 at one end
of the pallet 10
and the second end runner 24 positioned at an opposite end of the pallet 10,
the end walls 20c
and 20d face corresponding end walls in the end runner 24, as shown in Fig. 7.
The slat
grooves 20a and 20b receive the ends of the slats 12 and 14 and the end walls
20c and 20d
protect one of the ends of the slats 12 and 14 from being pried away from the
end runner 20,
and help position the slats 12 and 14 during construction. The corresponding
end walls in the
end runner 24 have a similar function to the end walls 20c and 20d and the
slat grooves 24a
and 24b (Fig. 7) receive the slats 12 and 14 in a manner similar to the slat
grooves 20a and
20b.
100561 The middle runner 22 is the second major component of the pallet 10,
and is
shown in Fig. 4 having two slat grooves 22a and 22b. The slat grooves 22a and
22b receive
the slats 12 and 14 in a manner similar to the slat grooves 20a and 20b. The
pin apertures 22e
and 22f are at the end of bores that extend into the middle runner and receive
the pins 30. The
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pin apertures 22e and 22f are centrally located, longitudinally and laterally
of the runner 22,
within the slat grooves 22a and 22b to permit reversal in the position of the
slats 12 and 14 in
the grooves. One middle runner 22 is used with the pallet 10, preferably
centrally located at
or near the middle of the pallet 10 as shown in Fig. 7, but it is contemplated
that for a longer
pallet there may be numerous middle runners 22. All runners 20-24 are oriented
substantially
parallel and spaced from one another in an operable orientation.
[0057] The slat 14 is the third major component of the pallet 10 and
is shown in Fig. 5
having angled or curved faces 14a and 14b. The slat 12 is substantially
identical to the slat 14
and therefore is not described in detail herein. The faces 14a and 14b are
preferably curved in
the direction from the top toward the bottom, and this can be seen in the end
view of the slat
14 shown in Fig. 6. The faces 14a and 14b are preferably not curved in the
longitudinal
direction (from one end of the slat 14 to the opposite end). When one compares
the face 14a
to the straight imaginary line 14e that is placed adjacent the face 14a in
Fig. 6, it can be seen
that the face 14a is concave, and this concavity provides benefits when it
receives a convex
outer surface of cargo. The face 14b is similarly concave, but this is not as
visible due to the
smaller width of the face 14b. Pin apertures 16 are formed in the slats 12 and
14, and are the
ends of bores that extend entirely through the slats as shown in Figs. 22 and
23.
[0058] As shown in Fig. 5, the slat 14 may have a plurality of U-
shaped strap-retainers
14d on its sides, which allow conventional cargo straps to be inserted through
an aperture
formed therein. These strap-retainers 14d prevent the straps from sliding
lengthwise along the
slat 14 (and the slat 12). Nesting guides 14e and 14f are additional features
formed at
opposite ends of the slat 14. Nesting guides 14e and 14f seat within cavities
formed on the
bottom of identical slats, as shown in Fig. 22 in phantom in the position
where they are
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located, that are stacked one upon the other. Two substantially identical
slats 12 and 14 are
used on the pallet 10, as shown in Figs. 11 and 12, and the nesting guides 14e
and 14f assist in
nesting if the slats 12 and 14 are stacked in a nesting configuration with one
on top of the
other. This may be done prior to assembly of the pallet 10.
[0059] Fig. 7 shows the runners 20, 22 and 24 aligned in preparation for
assembly of
the pallet 10. The runners 20-24 are aligned substantially parallel to one
another and
substantially equally spaced. Note that the end walls of the end runners 20
and 24 are at
opposite ends of the pallet 10. The pallet 10 will be assembled as shown and
described, and
the ends of the slats 12 and 14 are protected by the end walls when the pallet
10 is fully
assembled.
[0060] Once the runners 20-24 are positioned as in Fig. 7, the slat 14
is mounted in the
aligned series of slat grooves 20b, 22b and 24b in the runners 20-24 along one
longitudinal
end of each of the runners 20-24, as shown in Fig. 8, which is the lateral
side of the assembled
pallet 10. The pins 30 are inserted in the corresponding and aligned apertures
16 on the slat
14 and through the bores in each of the runners 20-24. The location of each of
the pins 30 is
shown in Fig. 9 (without the slat 14 in place) for illustrative purposes, and
the pins 30 are
preferably only inserted when a corresponding slat is in place on the runners
20-24. The pins
30 fix the slat 14 to the runners 20-24 in the manner of a bolt. A similar
illustration is shown
in Fig. 10, in which the pins 30 are shown in the location they will have when
the slat 12 is
mounted as shown in Fig. 11, but without the slat 12 in position. Again, this
is for illustrative
purposes only, because the pins 30 are preferably only in the position shown
in Fig. 10 when
the corresponding slat 12 is in place as shown in Figs. 11 and 12.
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[0061] Figs. 11 and 12 show the slats 12 and 14 mounted with their
longer faces 12a
and 14a closest to, and facing, one another. As shown in Fig. 14, the slats 12
and 14 can be
mounted with their shorter faces 12b and 14b facing one another, or in Fig. 13
with one long
face 14a and one short face 12b facing one another. Because the apertures 16
in the slats 12
and 14 align with the apertures 20e, 20f, 22e, 22f (and corresponding
apertures in the end
runner 24), regardless of orientation of the slats 12 and 14 in the slat
grooves, the invention
has immense flexibility in how it can be constructed. It is an advantage of
the present
invention that the slats 12 and 14 can be mounted in either orientation in the
grooves in the
runners 20-24. Because the apertures 20e, 20f, and others are centrally
located within the
corresponding slat grooves, the pins 30 can be used to fasten the slats to the
runners
regardless of the orientation of the slats 12 and 14. This allows the user to
best accommodate
the shape and size of the cargo placed on the pallet 10 by orienting the slats
12 and 14 to best
receive the cargo on their faces. Thus, if any of the configurations shown in
Figs. 12-14 best
suits the shape, size or other feature of the cargo, that configuration is
used by so arranging or
re-arranging the slats 12 and 14.
[0062] In Fig. 16, the pallet 10 is shown with the end runner 24
removed but with the
pins 30 in their location when the runner 24 is in place. This is for
illustrative purposes only,
and shows the location of the pins 30 when inserted into each of the runners
20-24 after
extending through the slats 12 and 14. Preferably the pins 30 would not be
installed in the
slats in this manner unless the end runner 24 is in place. In a preferred
embodiment, the end
of each pin with the slot 34s is inserted through the aperture 16 in the slat
12 or 14, and then
through the aperture 20e, 20f, etc. in the respective runner. On the bottom of
the runner, the
aperture's bore terminates above the lowest edge of the runner (see Fig. 21
for illustration of
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this in a mid-runner) by a distance greater than the thickness of the head 34,
thereby allowing
the head 34 of the pin 30 to spring open after exiting the aperture but to
remain protected so
that no part of the pin 30 supports the weight of the pallet 10 or its cargo.
[0063] The pallet 10 has cylindrical cargo 50, which may be a
pressure vessel, a metal
5 mold, a container or any other object, resting on the slats 12 and 14, as
shown in Fig. 17. The
diameter of the cargo 50 is such that it is best nested between the curved
faces 12a and 14a on
the slats 12 and 14 in their orientation shown in Fig. 17, which is similar to
that shown in
Figs. 2, 11, 12 and 15. For different diameter cargo, one or both of the slats
12 and 14 may be
reversed to the positions shown in Figs. 13 or 14 so that the cargo rests
against faces 12b and
10 14a or 12b and 14b.
[0064] The contemplated pallet 10 thus has slats 12 and 14 with faces
that
accommodate cargo from between about 14 to 20 inches in diameter, but with
modification of
the orientation, cargo up to about 24 inches in diameter can be readily
accommodated by the
same major components. Of course, the runners and slats of any given pallet
may be made
15 taller, longer and/or wider, and/or with slat grooves spaced farther
apart to accommodate
different-sized cargo. The curved faces on the slats can be of varying radius
of curvature
analogous to a "French curve", in order that one can select a position on the
curved faces to
rest the cargo.
[0065] The cargo 50 is mounted to the pallet 10 by cargo straps 52.
The cargo straps
preferably extend through the U-shaped strap-retainers 14d, 12d (see Fig. 12),
which are
identical to the retainers 14d and possibly similar U-shaped strap-retainers
(e.g., retainer 24d
in Fig. 17) mounted to the end runners 20 and 24. The cargo straps 52 may be
conventional
metal or woven polymer cargo straps.
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[0066] Fig. 18 shows the end runner 20 from a top view, and Fig. 19 is
the same end
runner 20 from a bottom view. Fig. 20 is a perspective view of the end runner
20. Fig. 21 is a
bottom perspective view of the mid runner 22, which shows where the bores of
the pin
apertures 22e and 22f terminate above the lowest point of the runner 22. The
bottoms of the
end runners 20 and 24 are very similar in at least this regard.
[0067] Figs. 22, 23, 24 and 25 show the slat 14 from the bottom, top,
short face side
and long face side, respectively. Fig. 27 shows the slat 14 from another
perspective, and Fig.
26 shows one end of the slat 14 in a more magnified view. Fig. 29 shows a
roughly
cylindrical object on a pallet made in accordance with the invention. Fig. 30
shows the end of
a pin that has expanded after insertion into a runner.
[0068] The end walls on the end runners 20 and 24 prevent or greatly
reduce the
possibility that a slat 12 and 14 may be pried off the pallet 10 during use,
whether
unintentionally or otherwise. If the fork of a forklift could be inserted
between the slats 12
and 14 and the runners 20-24, the fork could pry the slats from the runners.
Because of how
the slats rest in slat grooves in each of the runners 20-24, it is not likely
that a user would
unintentionally insert a fork between the slat and the runner from any of the
four sides of the
pallet 10. This can be seen in Fig. 15 where the end walls of both end runners
20 and 24
cover at least a portion of the ends of the slats 12 and 14, and the lateral
sides of the pallet 10
are also not exposed for fork insertion. This prevents access to a horizontal
crack between a
slat and a runner by a fork on a forklift. Such a fork placed in such a
horizontal crack could
separate the slats from the end runner, but this is virtually impossible with
the normal use of
the pallet 10.
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[0069] Based on the relative sizes of the slats 12 and 14, the slat
grooves in the
runners 20-24, pins and pin apertures, and the recessed positions of the pin
tips, the pins do
not bear any of the weight of the cargo. When weight rests on a slat, that
weight is transferred
to the corresponding runners only, not to any pins. The sizes of the slat
grooves are such that
if a slat receives a lateral force, the slat cannot be moved far enough
laterally relative to an
attached runner to place a shear force on a corresponding pin. This may be due
to the tight fit
of slats in the slat grooves compared to the loose fit of the pins in the
apertures, or to any
other relationship. Instead, the sidewalls and end walls of the slat grooves
stop the movement
of the slat before a shear force is applied to a pin. The pins connect the
slats and the runners,
so that when the cargo is lifted by a forklift's forks under the slats the
pins prevent the runners
from falling away from the slats.
[0070] In the illustrations, a pallet 10 is shown with two slats 12
and 14 and three
runners 20-24. It is contemplated that a pallet may be made with more than
three runners.
For example, a pallet may be constructed with five runners ¨ two end runners
and three mid
runners ¨ and two much longer slats. The pallet 10 may have an overall width
of forty inches
and a length of four feet, but the pallet 10 may be made much smaller or much
larger than this
typical pallet size. There are only practical limits to the number and size of
the completed
pallet, and this will become apparent to the person of ordinary skill.
[0071] The pallet is preferably made of polymer, as noted above, and
is cast or
injection molded into individual components that are assembled as described
herein. Of
course, it is contemplated to make the pallet of metal, wood, fiber-reinforced
polymer
composite, or any other suitable material, as will become apparent to the
person of ordinary
CA 02955038 2017-01-17
18
skill from the description herein, but such materials would present advantages
and
disadvantages that are known to the person of ordinary skill.
[0072] In the embodiment shown in Fig. 17, the pallet 10 is wider
than the cargo item
50. In this situation, the forks of the forklift extend under the pallet 10,
and the portion of the
forklift that extends upwardly from the ends of the forks nearest the lift
abuts the lateral edges
of the runners 20-24. This prevents the upwardly-extending portion from
impacting, and
possibly damaging the cargo 50 or the straps holding the cargo 50. An
alternative
embodiment of the invention is shown in Figs. 31-36. In the alternative
embodiment, the
pallet 110 is substantially identical to the pallet 10, but there are blockers
112a, 112b, 114a
and 114b mounted to at least one side of each of the slats 112 and 114. These
blockers 112a-
114b extend outwardly (laterally on a finished pallet) of the runners 120, 122
and 124 for
stopping the upwardly-extending portion of the forklift from impacting the
cargo. The
blockers 112a-114b are shown attached to the sides of the slats 112 and 114
that have the
short faces, but it is contemplated that blockers 112a-114b may be attached to
either side (or
both sides) of the slats 112 and 114. The blockers on opposite sides may be of
different size
or shape.
[0073] As shown in the end view of Fig. 32 and the top view of Fig.
34, the blockers
112a-114b extend, at their outermost extremity, to beyond the lateral
extremity of the pallet
110, which is the longitudinal extremity of the runner 124, and the other
runners 120 and 122.
The blockers 112a-114b present a surface against which the upwardly-extending
portion of
the forklift may seat during use, rather than seating against the cargo 150
that extends beyond
the extremities of the pallet 110 as shown in Fig. 33. The imaginary line A
extends parallel to
the plane of the end of the runner 124, and the imaginary line B extends
parallel to the line A
CA 02955038 2017-01-17
=
19
at the outermost extremity, or the tip 114b', of the blocker 114b. It is
apparent that if the
forklift were only to be stopped by the end runner 124, and the corresponding
ends of the
runners 120 and 122, the upwardly-extending portion of the forklift could
impact the cargo
before impacting the runners 120-124. However, because the tip 114b' of the
blocker 114b
extends laterally beyond the ends of the runners 120-124, the upwardly-
extending portion of
the forklift would only impact the tip 114b' of the blocker 114b, which is at
line B.
[0074] There may be times when the blockers 112a-114b are not needed,
or are a
hindrance to the use of the pallet 110, and in those situations the slats 112
and 114 may be
reversed to the positions shown in Figs. 35 and 36. In the position shown, the
blockers 112a-
114b extend inwardly toward one another, because the slats 112 and 14 have
been oriented
180 degrees from the positions shown in Figs. 31-34. The blockers 112a-114b
preferably
have tips that are formed with an interlacing structure, thereby permitting
the tips to extend as
far as is desired from the slats 112 and 114, but still fitting with the space
allowed between
one another when reversed. As an example, if the blockers 112a-114b were each
7 inches
long to extend a desired distance from the slats 112 and 114, but only a 12
inch wide gap was
formed between the slats 112 and 114, there would be insufficient space for
the blockers
112a-114b to be reversed to face one another if the tips thereof were
straight. However, by
forming the shown and described interlacing structure, at least some portions
of the blockers
112a-114b extend the desired distance, and other portions extend far less.
When the blockers
112a-114b are thus interlaced as shown in Figs. 35 and 36, there is sufficient
space for
blockers to face one another.
100751 The above interlacing structure is shown and described herein,
in one example,
with peaks 212, 216, 312 and 316 and valleys 214, 218, 314 and 318 on the
blockers 112a-
CA 02955038 2017-01-17
114b shown in Fig. 34. The peaks 212, 216, 312 and 316 extend away from the
slats 112 and
114 substantially farther than the valleys 214, 218, 314 and 318. Furthermore,
the valleys
214, 218, 314 and 318 are voids that receive the peaks 212, 216, 312 and 316
when the
blockers 112a-114b face one another as shown in Figs. 35 and 36. Thus, the
longer the peaks
5 212, 216, 312 and 316 are, the deeper the valleys 214, 218, 314 and 318
need to be. Of
course, other alternative structures may be used in place of the example shown
herein, as will
become apparent to a person having ordinary skill, including blockers (not
shown) that extend
one length from one side of a slat, and separate blockers that extend a
different length from
the opposite side of the same slat.
10 [0076] This detailed description in connection with the drawings
is intended
principally as a description of the presently preferred embodiments of the
invention, and is
not intended to represent the only form in which the present invention may be
constructed or
utilized. The description sets forth the designs, functions, means, and
methods of
implementing the invention in connection with the illustrated embodiments. It
is to be
15 understood, however, that the same or equivalent functions and features
may be accomplished
by different embodiments that are also intended to be encompassed within the
spirit and scope
of the invention and that various modifications may be adopted without
departing from the
invention or scope of the following claims.
