FIELD OF THE INVENTION
This invention relates generally to pallets, and more particularly, to convertible pallets that may be disassembled.
BACKGROUND OF THE INVENTION
Many companies throughout the world participate in trade shows. Many of these entities utilize specially built furniture to support their displays in the trade shows. The movement of displays and furniture and other large objects is typically facilitated at such trade shows by the use of pallets, which are platforms or supporting structures used to hold and move large, heavy and bulky objects. Pallets typically have a somewhat standard structure that allows a fork-lift, or other heavy machinery to lift and move loaded or unloaded pallets from one place to another. Of course, the use of pallets is not restricted to trade shows. Pallets may be used to hold and move large, heavy and bulky objects in any environment.
One of the most difficult and expensive aspects of participating in trade shows is the assembly, disassembly, and movement of the display and furniture. In addition, once the display is setup, the pallets are stored for use until it is time to disassemble the display. Often times, the company representatives must wait several hours for the return of these pallets before they can repack their display booths. The need to store the pallets may therefore add significant problems and costs to the process of setting up for a trade show. In addition, the rental of furniture for an exhibiting company represents a very high cost.
While there have been a number of pallet designs and related devices, there is a need for a system in which a pallet may be easily disassembled for easy storage. There is also a need for systems that may be easily disassembled and re-assembled as equipment having alternative functions.
SUMMARY OF THE INVENTION
In view of the above, a method is provided for converting a pallet to alternative use equipment. In an example implementation of the method, a pallet assembly having a pallet support structure formed by beam members attached to transverse members and a plurality of pallet surface components attached to intersecting areas formed at the areas of attachment of the transverse members and the beam members. The pallet assembly may be disassembled by detaching the pallet surface components from the intersecting areas, and by detaching the beam members from the transverse members.
In another aspect of the method, the extension members may be attached to conversion enabling structure on the pallet surface components to assemble a selected piece of equipment.
In another aspect of the invention, a pallet assembly is provided configured to be disassembled as pieces that are easier to store than entire pallet assemblies. One example pallet assembly includes a plurality of beam members. A plurality of transverse members are configured to connect to the beam members. A pallet support structure is formed by having at least two of the transverse members connected to the sides of at least one pair of beam members. The pallet support structure is formed so as to define areas of intersection where the transverse members and beam members attach. A plurality of pallet surface components are configured to fit over the areas of intersection on the pallet support structure to form a substantially flat surface and, with the pallet support structure, to function as a pallet.
In another aspect of the invention, the pallet surface components may include a conversion enabling structure to receive selected components that convert at least the pallet surface components to pieces of equipment that do not function as pallets when detached from the pallet support structure.
Other devices, apparatus, systems, methods, features and advantages of the examples consistent with the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Examples of systems and methods consistent with the present invention are described below with reference to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1 is a top perspective view of an example pallet assembly.
FIG. 2 is a perspective exploded view of the example pallet assembly in FIG.
FIG. 3 is a bottom perspective view of the example pallet assembly in FIG. 1.
FIG. 4A is a top perspective view of an example pallet support structure of the example pallet assembly in FIG. 1.
FIG. 4B is a top view of the example pallet support structure in FIG. 4A.
FIG. 4C is a cross-sectional view of the example pallet support structure in FIG. 4A at the cross-section defined by A-A′.
FIG. 4D is a cross-sectional view of the example pallet support structure in FIG. 4A at the cross-section defined by C-C′.
FIG. 5 is a bottom perspective view of an example pallet surface component used in the example pallet assembly in FIG. 1.
FIG. 6 is an example internal cross-member used in the example pallet support structure of the example pallet assembly in FIG. 1.
FIG. 7 is a perspective view of an example coffee table assembled with the example pallet surface component in FIG. 5.
FIG. 8 is an exploded perspective view of the example coffee table in FIG. 7.
FIG. 9 is a perspective view of an example table assembled with multiple pallet surface components in FIG. 5.
FIG. 10 is an exploded perspective view of the example table in FIG. 9.
FIG. 11 is a perspective view of an example shelving unit assembled with multiple pallet surface components in FIG. 5.
FIG. 12 is an exploded perspective view of the example shelving unit in FIG. 11.
FIG. 13 is a perspective view of an example chair assembled with a pallet surface component in FIG. 5.
FIG. 14 is an exploded perspective view of the example chair in FIG. 13.
DETAILED DESCRIPTION
FIG. 1 is a top perspective view of an example pallet assembly 100. The pallet assembly 100 may be disassembled to components that may be re-assembled as other pieces of equipment. Disassembly of the pallet assembly may mean disassembly into various completely disassembled parts or into components that include a collapsed structure. The pallet assembly 100 includes a plurality of pallet surface components 102 and a plurality of pallet support structure components 104. The pallet surface components 102 may be formed to fit over a pallet support structure formed by the pallet support structure components 104. The pallet assembly 100 in FIG. 1 may be used as a typical pallet by attaching pallet lifting beams 106 to the underside of the pallet assembly 100. Large objects may be placed on the top surface 106 formed by the plurality of pallet surface components 102. The pallet assembly 100 may be supported by the pallet support structure components 104 and the pallet lifting beams 106. The pallet lifting beams 106 may be attached with sufficient space between them to fit a forklift underneath. The pallet lifting beams 106 may be attached using bolts, or any other suitable attaching mechanism. In another example, the pallet lifting beams 106 may be fixed to the pallet support structure components 104.
FIG. 2 is a perspective exploded view of the example pallet assembly in FIG. 1. The plurality of pallet surface components 102 may lift off a pallet support structure 202 formed by the pallet support structure components 104. The pallet support structure components 104 may include a pair of beam members 204 attached to one or more transverse members 206. The transverse members 206 may be placed substantially in parallel with one another and attached at their ends to the beam members 204. The beam members 204 are “attached” to the transverse members 206 using an attachment mechanism that permits repeated detachment and re-attachment. In addition, the transverse members 206 may be attached to the beam members 204 and detached by collapsing to a structure in which the beam members 204 and transverse members 206 do not form intersecting areas. In the collapsed structure, the beam members 204 may remain in contact with the transverse members 206, but in contact via a hinge or other supporting structure that keeps the beam members 204 and transverse members 206 together in the collapsed structure.
The pallet assembly 100 in FIG. 2 includes three beam members 204a-c. Three transverse members 206a-c are attached between the first and second beam members 204a and 204b. Three additional transverse members (only two transverse members 206d and 206e are visible in FIG. 2) are attached between the second and third beam members 204b and 204c. The pallet assembly 100 in FIG. 2 also includes end members 208a-c extending substantially perpendicular to the first beam member 204a, and three end members (only two end members 208d and 208e are visible in FIG. 2) extending substantially perpendicular to the third beam member 204c. The end members 208a-c are connected to the first beam member 204a substantially at the points of attachment of the three transverse members 206a-c. The end members 208d-f are connected to the third beam member 204c substantially at the points of attachment of transverse members 206d, 206e, and the transverse member that is not visible in FIG. 2.
The beam members 204 and transverse members 206 when assembled form a lattice-like structure having areas of intersection between the beam members 204 and the transverse members 206. The pallet surface components 102 are formed to fit on and cover the points of intersection. The pallet surface components 102 may have a planar, rectangular top surface 210. The pallet surface components 102 shown in FIG. 2 have a square planar top surface 210. The top surface 210 includes a side surface 212 extending downward from each edge of the top surface 210. Each side surface 212 includes an opening 214 dimensioned to receive either the beam members 204 or the transverse members 206 of the pallet support structure 104. The pallet surface component 102 may be placed over the point of intersection formed at the point where transverse members 206 opposite one of the beam members 204. Two openings 214 on opposite sides of the pallet surface component 102 fit over the beam member 204 and the other two openings 214 fit over the transverse members 206. The dimensions of the pallet surface components 102 may be such that the pallet surface components 102 come together at the top surface 210 edges to form a flat surface over the pallet support structure 104 when each point of intersection is covered by one of the pallet surface components 102.
The pallet lifting beams 106 are not shown in FIG. 2. However, the may be attached to either the underside of the beam members 204, between the beam members 204, to the underside of the transverse members 206, or between the transverse members 206. The pallet lifting beams 106 may also be fixed to the underside of the beam members 204, such that the two members for a unit.
It is to be understood by those of ordinary skill in the art that the pallet support structure 104 described with reference to FIG. 2 is but one example of a pallet support structure. Other structures may be used as well. For example, the pallet support structure 104 may be at least partially collapsible into one or more structures suitable for conversion to other pieces of equipment.
FIG. 3 is a bottom perspective view of the example pallet assembly 100 in FIG. 1. The pallet assembly 100 includes the pallet support structure 104, which includes the beam members 204, the transverse members 206, and end members 210 assembled as described above with reference to FIGS. 1 and 2. FIG. 3 shows the bottom view of the pallet surface components 102 depicting corner sections 302 formed by the openings 214 in the sides 212 of the pallet surface components 102. Each corner section 302 may include a conversion enabling structure 304 or other structure that may be used to insert components that permit conversion of the pallet surface components 102 to other types of equipment as described in more detail below with reference to FIGS. 7-14. The conversion enabling structure 304 may be any suitable shape consistent with the components used to make the other types of equipment. The conversion enabling structure 304 in FIG. 3 is a round hole configured to fit a rod-like structure when inserted into the conversion enabling structure 304. The conversion enabling structure 304 in FIG. 3 is but one example structure. Other shapes and mechanisms maybe used as well.
FIG. 4A is a top perspective view of an example assembled pallet support structure 104 of the example pallet assembly 100 in FIG. 1. FIG. 4A shows the transverse members 206 and end members 208 attached to the beam members 204. The transverse members 206 and end members 208 attach to the beam members 204 at areas of intersection 402. The pallet surface components 102 may be placed over the areas of intersection 402 to form a pallet. The transverse members 206 and end members 208 may be attached to the beam members 204 using bolts, screws, or other detachable attachment devices at, for example, attachment points 404. In alternative example structures, the transverse members 206, end members 208 and/or beam members 204 may not require detachment from one another, and may be collapsible when disassembled to convert to other equipment.
The pallet support structure 104 such as the one in FIG. 4A provides the rigidity and support to function as a pallet. Those of ordinary skill in the art will appreciate that the structure 104 is but one example of a pallet supporting structure.
FIG. 4B is a top view of the example pallet support structure 104 in FIG. 4A. The beam members 204 are connected to the transverse members 206 and end members 208 to form the support and areas of intersection 402 on which the pallet surface components 102 (FIG. 1) are placed to form the pallet.
FIG. 4C is a cross-sectional view of the example pallet support structure in FIG. 4A at the cross-section defined by A-A′. FIG. 4C shows points at which transverse members are attached as four holes 410 through which detachable attachment devices are implemented.
FIG. 4D is a cross-sectional view of the example pallet support structure in FIG. 4A at the cross-section defined by C-C′. The view at the cross-section defined by C-C′ shows an example of how transverse members 206 (or end members 208) may be attached to the beam members 204. As shown in FIG. 4D, the transverse members 206 include a pair of attachment flaps 420 with holes configured to align with the beam member holes 410 for implementation of the detachable attachment devices. For example, a bolt may be inserted in the holes of the attachment flaps 420 to go through the beam member holes 410 and through the attachment flaps 420 of the transverse member 204 (or end member 206) on the opposite side of the beam member 204. Those of ordinary skill in the art will appreciate that FIG. 4D shows but one example of how the transverse members 206 may be attached to the beam members 204. Attachment of the transverse members 206 to the beam members 204 may be accomplished using any suitable means.
FIG. 5 is a bottom perspective view of an example pallet surface component 102 used in the example pallet assembly in FIG. 1. FIG. 1 shows the side surfaces 212 with openings 214. The openings 214 have a width w, which is selected to be sufficient for either one of the beam member 204 or the transverse member 206 to fit. The openings 214 and side surfaces 212 form corner sections 302 on the pallet surface component 102. The corner section 302 may include a conversion enabling structure 304 that may be used to receive a component that enables conversion of the pallet surface component 102 to another type of equipment.
The pallet surface component 102 includes a pallet attachment enabler 502 to enable fastening of the pallet surface component 102 to the pallet support structure 104 (FIG. 1). For example, a bolt or screw or other attaching device type may be inserted in the pallet attachment enabler 502 and received by a complementary attachment enabler in the beam member 204 or transverse member 206.
The holes 304 for receiving structure that may be used to receive a component that enables conversion of the pallet surface component 102 to another type of equipment may include a secure attachment enabler 504 to receive a mechanism for securing the component. In one example, a cotter pin may be inserted in the secure attachment enabler 504 to secure the component to the pallet surface component 102. Other implementations may be used instead.
FIG. 6 is an example transverse member 206 that may be used in the example pallet support structure 104 of the example pallet assembly 100 in FIG. 1. The transverse member 206 includes a first and second attachment portions 602a and 602b on opposite ends of the transverse member 206. The attachment portions 602a,b are attached to opposite ends of a main transverse member 606. The main transverse member 606 in FIG. 6 is rectangular with substantially planar surfaces having a length and a width, and a thickness separating the planar surfaces. The main transverse member 606 functions to provide weight-bearing support to the pallet assembly 100 in the direction normal to the beam members 204 (FIG. 2). The main transverse member 606 provides the weight-bearing support by being mounted with the planar surfaces oriented substantially perpendicular to the pallet surface. The transverse member 206 also includes a first and second support plate 604a,b fixed to opposite edges of the main transverse member 606. The support plates 604a,b provide a surface that contacts the bottom surface of the pallet surface components 102 when assembled as a pallet.
The attachment portions 602a,b include one or more attachment enablers 608 to enable fastening the attachment portion 602a to the beam members 204. The attachment enablers 608 in FIG. 6 are holes through which bolts, screws, or other rod-like attachment devices may be inserted to fasten the transverse member 206 to the beam member 204.
The transverse member 206 may be made of metal (such as aluminum, steel, or any other suitable metal or alloy), plastics/polymers, wood, or any other suitable substantially rigid material. The transverse member 206 may be cast, or assembled by, for example, welding the attachment portions 602 and support plates 604 to the main transverse member 606.
As described above, when the pallet assembly 100 is disassembled (which may be disassembly by collapsing the pallet support structure), the pallet surface components 102 and the pallet support structure components 104 may be re-assembled as different types of equipment, such as for example, furniture. FIGS. 7-14 illustrate examples of furniture that may be assembled using pallet surface components 102 and pallet support structure components 104 used for the pallet assembly 100. In general, the pieces of equipment may be assembled by attaching vertical support extension members to the pallet surface components 102 of the pallet assembly to assemble a desired piece of equipment. FIGS. 7-14 illustrate assembling the components to convert the structure to furniture. Those of ordinary skill in the art will appreciate that any type of equipment may be similarly constructed.
FIG. 7 is a perspective view of an example coffee table 700 assembled with the example pallet surface component 102 in FIG. 5. The coffee table 700 includes the pallet surface component 102 and four table legs 702a-d, which are the vertical support extension members. The table legs 702a-d are attached to the pallet surface component 102 at the corner sections 302 of the pallet surface component 102.
FIG. 8 is an exploded perspective view of the example coffee table 700 in FIG. 7. FIG. 8 illustrates how the coffee table 700 may be assembled using the pallet surface component 102. The coffee table 700 may be assembled by inserting extended part fasteners 802a-d into fastener receiving holes 304 in the corner sections 302 of the pallet surface component 102. The extended part fasteners 802a-d may include a cylindrical portion 804a-d extending from a block portion 806a-d. The cylindrical portion 804 may be formed to fit the fastener receiving holes 304 in the corner sections 302 of the pallet surface components 102. The block portions 806 may be dimensioned to fit inside a hollow end 808a-d of each table leg 702a-d. Each leg 702a-d may include a spring clip 810a-d attached to the surface block portions. The hollow ends 808a-d of the table legs 702a-d may include structure to allow the legs 702a-d to snap into the fasteners 802a-d. The springs 810a-d may be used to prevent wobble by the legs 702a-d.
The table 700 in FIGS. 7 and 8 may also include a seat cover 720 that maybe configured to fit into the top of the pallet surface component 102. For example, the seat cover 720 may include protrusions dimensioned to fit into corresponding holes on the pallet surface component 102. The table 700 may also include leg pads 814 that may be press fit in a hollow end 816 of the table legs 702 to provide a more slippery surface contact with the floor.
FIG. 9 is a perspective view of another example table 900 assembled with multiple pallet surface components in FIG. 5. The table 900 in FIG. 9 includes six (6) pallet surface components 102 mounted on a partial pallet support structure 902 to form a substantially flat table top 905. The table top 905 may be supported by four legs 904 extending from the corner sections 302 of the four pallet surface components 102 on the corners of the table top 905. The four legs 904 may be connected to corresponding cross-member fasteners 912, which may connect to length-wise cross-members 906 and width-wise cross-members 908 to provide the table 900 with stability. Each leg 904 may also have an end extension 910 to extend to contact the floor.
FIG. 10 is an exploded perspective view of the example table 900 in FIG. 9. The table top 905 in FIG. 10 is formed with six (6) pallet surface components 102. The partial pallet support structure 902 includes two beam members 204 joined to three transverse members 206. The beam members 204 and transverse members 206 may be joined in a manner similar to that described above with reference to FIGS. 1-6. The pallet surface components 102 may be attached to the partial pallet support structure 902 by fastening the pallet surface components 102 to beam members 204. For example, the pallet surface components 102 may be attached by screws, bolts, or other suitable attachment devices at attachment holes 1002 in the pallet surface components 102 and corresponding attachment holes 1004 in the beam members 204. The legs 904 may be attached to the corner sections 302 of the pallet surface components 102 using the extended part fasteners 802 and spring clips 810 as described above for the coffee table 700 with reference to FIGS. 7 and 8. The legs 904 in FIG. 10 are connected to cross-member fasteners 912, which are also connected to corresponding length-wise and width-wise cross-members 906, 908. The cross-member fasteners 912 connect to leg ends 910, which may be fitted with leg pads 1006.
FIG. 11 is a perspective view of an example shelving unit 1100 assembled with multiple pallet surface components 102 in FIG. 5. The shelving unit 1100 in FIG. 11 includes three pallet surface components 102, which provide the surfaces to be used as shelves. Two of the pallet surfaces 1102 are supported by four top extension members 1104a. Four extension members 1104 attach to the bottom side of a top pallet surface component 1102a and to the top side of the middle pallet surface component 1102b of the shelving unit 1100. The lower extension members 1104 are attached to the top surface of a bottom pallet surface component 1102c.
FIG. 12 is an exploded perspective view of the example shelving unit 1100 in FIG. 11. FIG. 11 illustrates how the shelving unit 1100 may be assembled. The four top extension members 1104a may be attached to the bottom side of the top shelf pallet surface component 1102a. The top extension members 1104a may be attached as described above for the coffee table 700 with reference to FIG. 8 using the extended part fasteners 802, and spring clips 810. The extended part fasteners 802 may be turned over to fit over the opposite ends of the top extension members 1104a. The cylindrical portion of the extended part fasteners 802 may be press-fit, or fastened with attachment devices such as screws, bolts etc. into corresponding holes 1106 on the top side of the middle shelf pallet surface component 1102b.
Similarly, the bottom extension members 1104b may be attached to the bottom side of the middle shelf pallet surface component 1102b as described above for the coffee table 700 with reference to FIG. 8 using the extended part fasteners 802, and spring clips 810. The extended part fasteners 802 may be turned over to fit over the opposite ends of the bottom extension members 1104b. The cylindrical portion of the extended part fasteners 802 may be press-fit, or fastened with attachment devices such as screws, bolts, etc. into corresponding holes 1106 on the top side of the bottom shelf pallet surface component 1102c.
FIG. 13 is a perspective view of an example chair 1300 assembled with a pallet surface component 102 in FIG. 5. The pallet surface component 102 is the seat of the chair 1300. The chair 1300 in FIG. 13 includes a seat cover 1302 on the pallet surface component 102. A set of upper extender parts 1304a,b extends from two of the a top-side corners 1306a,b of the pallet surface component 102. A seat backing 1308 fits over the opposite ends of the upper extender parts 1304a,b. Four lower extender parts 1310a-d extend from the bottom-side of the pallet surface component 102 to form legs. The opposite ends of the lower extender parts 1310a-d connect to cross-member fasteners 1312a-d, which connect to corresponding cross-members 1314a-d. The cross-member fasteners 1312 also connect to leg extenders 1318a-d, which provide footing for contact to the floor.
FIG. 14 is an exploded perspective view of the example chair 1300 in FIG. 13. FIG. 14 illustrates how the chair 1300 may be assembled. The pallet surface component 102 is the seat of the chair 1300 and includes the upper extender parts 1304a,b attached to the top-side corner 1306 of the pallet surface component 102 via the extended part fastener 802. As described above, the cylindrical part of the extended part fastener 802 may be inserted into a corresponding receiving hole on the pallet surface component 102. The block part of the extended part fastener 802 fits inside the upper extender parts 1304a. The seat backing 1308 may be made to slip on to the ends of the upper extender parts 1304a,b.
As shown in FIG. 14, the lower extender parts 1310a-d may be attached to the corner sections 302 of the pallet surface component 102 as described above for the coffee table 700 with reference to FIG. 8. The lower extender parts 1310a-d may attach to cross-member fasteners 1312a-d, which may attach to cross-members 1314a-d. Leg extenders 1318a-d may be connected to the cross-member fasteners 1312a-d to provide contact to the floor via floor pads 1402.
The foregoing description of examples and implementations has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. As an example, although the above examples of the present invention have been described in the context of shelving and tables, the teachings of the invention are applicable to an unlimited variety of types of equipment, including cabinets, lockable cabinets, podiums, desks, chairs, shelves, and any type of furniture. The equipment may also be structures that are not furniture, but instead have other functions. The claims and their equivalents define the scope of the invention.