Pallet

Abstract

In one example, a pallet is disclosed comprising a first pallet comprising a first side wall. The first wall has a length and a first groove lying in a plane and extending along the entire length. A second pallet comprising a second side wall is adjacent to the first side wall. The second side wall has a second length and a second groove lying in the plane and extending along the entire second length. The second groove faces the first groove and is aligned with the first groove in the plane, along the entire first and second lengths. A connecting member is within the aligned first and second grooves to connect the first and second pallets. Two unit, four unit, and larger pallets may be made. A method of using such pallets is also described.

Description

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of an example of a subpallet 12 used in embodiments of the present invention;

FIG. 2 is a perspective view of two subpallets coupled to each another by a connecting plate, to form a two unit pallet, in accordance with an embodiment of the invention;

FIG. 2 a is a perspective view of an example of the connecting plate of FIG. 2;

FIG. 3 is a perspective view of four subpallets coupled to each other by the connecting plate to form a four unit pallet, in accordance with an embodiment of the invention;

FIG. 4 is a rear view of the subpallet of FIG. 1;

FIG. 5 is a perspective view of the four unit pallet of FIG. 3 being engaged by a forklift;

FIG. 6 is a front perspective view of products strapped to a sub pallet and wrapped in plastic;

FIG. 7 is a front view of the subpallet of FIG. 2;

FIG. 8 is a front perspective view of products stocked on a four unit pallet, wrapped in plastic;

FIG. 9 is a perspective view of a four unit pallet with product stacked on one of four pallets;

FIG. 10 is a perspective view of a four unit pallet, stacked with different products;

FIG. 11 is a perspective view of another example of a subpallet that may be used in embodiments of the present invention;

FIG. 12 is a front view of a first subpallet coupled to pallets on both sides of the first subpallet;

FIG. 13 is a side view of an example of a clamp that may be snapped around portions of adjacent subpallets;

FIG. 14 is a perspective view of an example of a four unit master pallet including the clamps of FIG. 13;

FIG. 15 is a perspective view of an example of another four unit master pallet secured by clamps received in openings in adjacent subpallets;

FIG. 16 is a side view of another example of a clamp or sleeve that may be fit over the top and bottom surfaces of adjacent subpallets; and

FIG. 17 is a perspective view of a four unit master pallet including the sleeves of FIG. 16.

DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 is a perspective view of a subpallet 12 that may be used in embodiments of the present invention. FIG. 2 is a perspective view of two subpallets 12, 14 coupled to each another by a connecting plate 34, to form a two unit master pallet 15, in accordance with an embodiment of the invention. FIG. 2a is a perspective view of an example of the connecting plate 34 of FIG. 2, having a length CPL. FIG. 3 is a perspective view of four subpallets 12, 14, 12′, 14′ coupled to each other by the connecting plate 34 to form a four unit master pallet 17, in accordance with an embodiment of the invention. FIG. 4 is a rear view of the subpallet 12 of FIG. 1.

The subpallet 12 comprises an upper surface 16, which in this example comprises a supporting plate 16, and a base or lower surface 18, which in this example comprises a plate 18, as shown in FIGS. 1 and 4, for example. The supporting plate 16 is connected to the base plate 18 by rectangular blocks 20, 22, which are positioned to form a space 24 to receive one or more forklift or handlift blades 28, as shown in FIG. 5, for example. In this example, each subpallet 12, 14, 12′, 14′ is the same as or is a mirror image of the subpallet 12 of FIG. 1.

In use, the base plates 18 of the two unit master pallet 15 and the four unit master pallet 17 may rest on the ground, as shown in FIGS. 6, and 8, for example. The base plate 18 is optional. Lower surfaces of the blocks 20, 22 may rest directly on the ground or another layer of material (not shown) may be coupled to the blocks. The layer of material need not span the space between the blocks, as does the base plate 18. The blocks 20 and 22 may also include openings to receive forklift/handlift blades.

FIG. 5 shows a portion of a forklift 26 with blades 28 being inserted into the spaces 24 of two subpallets 12, 14 of a four unit master pallet 17. In this Figure, product P is stacked on only one of the subpallets, for ease of illustration. Products may be stacked on all or any number of the subpallets 12, 14, 12′, 14′.

The plates 16, 18 and the blocks 20, 22 may comprise plywood, oriented strand board (“OSB”), corrugated cardboard, solid wood, plastic, or metal, for example. Each block 20, 22 may comprise multiple layers of material. The blocks 20, 22 may be glued to the supporting plate 16 and base plate 18 with furniture glue, for example. The blocks 20, 22 may be connected to the plates 16, 18 by other means, such as by screws, nuts, bolts, nails, etc., instead of or along with the glue. The plates 16, 18 and the blocks 20, 22 need to be of a suitable material and size to be strong enough to support the expected load on the subpallet.

The rectangular blocks 20, 22 in each subpallet 12, 14, 12′, 14′ may include opposing respective slots 30 to receive belts 31 to secure the products to the subpallets 12, 14, 12′, 14′, as shown in FIGS. 1-3 and 6, for example. The belts 31 may be plastic belts, for example. The belts may be of other materials, as well. The belts 31, which may be secured beneath the plate 16, such as on a lower surface of the plate 16, exit both slots 30 from beneath the plate 16, and are strapped around the products on the subpallet, as shown in FIG. 6, for example.

An exterior surface or sidewall 22a of one block, in this example, the block 22, in each subpallet 12, 14, 12′, 14′ includes an opening, such as a groove 32, as shown in FIGS. 1 and 4, for example). In accordance with one embodiment, in the example FIGS. 1 and 2, the grooves 32 extend along the entire length L1 of the subpallets 12, 14. In this example, the connecting plate 34 has a length CPL that is about the same as the length L1 of the grooves 32. In accordance with another embodiment of the invention, in a two unit master pallet 15, the connecting plate 34 extends at least half way across the length L1 of the subpallets 12, 14. The grooves 32 may extend at least half way across the length (and at least the same extent as the connecting plate 34), as well. The grooves 32 may extend completely across the length L1 of the subpallets even if the connecting member 34 does not. While the subpallets 12, 14 typically have the same lengths, that is not required. If the lengths are different, the connecting plate 34 is provided with a sufficient length CPL to extend at least halfway across the length of either or both pallets. The connecting plate 34 may extend at least half way along the long pallet or at least half way along the shorter pallet.

FIG. 7 is a front view of the subpallets 12, 14. To form the two unit master pallet 15, the subpallet 12 and the subpallet 14 are placed next to each other so that the respective sidewalls face each other and the grooves 32 are aligned in a first plane, such as a horizontal plane H, to form a larger groove, as shown in FIG. 7. The subpallets 12, 14 may be positioned so that the sidewalls are adjacent to each other, by a forklift 26 or handlift, for example. A connecting member, such as the rectangular plate 34 of FIG. 2a, is then slid into the opening, here the larger groove, interlocking the two subpallets 12, 14 to hold them together, as shown in FIG. 2 and FIG. 7, for example.

In the example of the four unit master pallet 17 of FIG. 3, the grooves 32 extend completely across the length L2 of the master pallet and the length CPL of the connecting plate 34 is about the same as the length L2 of the master pallet. In accordance with another embodiment, the connecting plate 34 may have a sufficient length CPL to extend completely across the first, front pallets 12, 14, and at least half way across the second, rear pallets 12′, 14′. The corresponding grooves 32 extend at least half way across the lengths of the subpallets 12′, 14′, as well, at least as far as the connecting plate 34 will extend. They may extend across the entire length L2 of the master pallet 17, even if the connecting plate 34 does not. As above, while the subpallets 12, 14, 12′, 14′ typically have the same lengths L1, that is not required. If the lengths are different, the connecting plate 34 has a sufficient length CPL to extend at least halfway across the length of either or both subpallets 12′, 14′. The connecting plate 34 may extend at least half way along the longer pallet or at least half way along the shorter pallet.

Each subpallet 12, 14 also comprises a front face 12a, 14a and a rear face 12b, 14b, respectively, as shown in FIG. 2. To form the four unit master pallet 17, each of the subpallets 12′ and 14′ are positioned by the forklift 26 or handlift so that the rear faces 12b, 14b of subpallets 12, 14 are adjacent to the front faces 12a, 14a of subpallets 12′, 14′, as shown in FIG. 3. The respective grooves 32 in the sidewalls of the subpallets 12′, 14′ also face each other in alignment in the horizontal plane H (see FIG. 7) and are also aligned with the grooves 32 of the subpallets 12, 14 in the horizontal plane H. The connecting plate 34 is then inserted into the aligned grooves 32 of the four subpallets 12, 14, 12′, 14′ interlocking them to form the four unit master pallet 17. The subpallets 12, 14, 12′, 14′ may be stacked prior to positioning to form the master pallet, or not.

The connecting plate 34 may be inserted into the groove 32 manually or by the forklift 26, or handlift for example. The connecting plate 34 may comprise wood, plywood, OSB, corrugated cardboard, metal, plastic or another material that may be selected by one skilled in the art to provide the required strength to hold the subpallets 12, 14, 12′, 14′ together and to support desired products or weight, as is known in the art. As shown in FIGS. 2, 2a, and 3, for example, a member, such as a string or rope 35, may be provided at one or both ends of the connecting plate 34, to facilitate manual removal of the connecting plate 34 by pulling on the member 35. The connecting plate 34 could thereby be removed, even if the length of the plate is less than the lengths of the grooves 32, as long as the rope or string 35 extends out of the grooves 32 or is accessible.

The groove 34 may be compressed when product is stacked on the subpallets. The height dimensions of the grooves 32 when product is stacked on a subpallet is such that the connecting plate 34 can be inserted into the grooves and fit snugly to interlock the subpallets. The height dimensions of the grooves 32 when stacked may be about the same as the height dimension of the plate. When not stacked, the height dimension of the grooves 32 may be about the same as or slightly greater than the height dimension of the plate 34.

In one example, products may be separately stacked on each of the two subpallets 12, 14 or four subpallets 12, 14, 12′, 14′. After stacking, the products may be strapped to the respective subpallet 12, 14, 12′, 14′ by the belts 31, as shown in FIG. 6. Each of the stacked products on each subpallet 12, 14, 12′, 14′ may then be separately wrapped with plastic wrap 37, such as transparent plastic wrap from Poly-America, Grand Prairie, Tex., for example, as is known in the art. FIG. 9 also shows product P on one subpallet 12′ of a four unit master pallet 17.

Plastic wrap 39 may also be wrapped around the products supported on two adjacent subpallets, such as in the two unit master pallet 15 or around the products supported on four subpallets, such as in the four unit master pallet 17, as shown in FIG. 8. Each subpallet may already be individually wrapped by plastic wrap 37. The plastic wrap 39 may be a polyethylene film, such as Blue Color Stretch Wrap Film, for example, available from Poly-America, Grand Prairie, Tex., for example. The plastic wrap 39 may include guide lines (not shown) along which the wrap may be cut to access the products stacked on the subpallets. The guide lines may be configured to facilitate opening along those lines by perforations, for example. The master pallet unit 15, 17 may then be loaded inside a container for shipping, as would a typical pallet. The same amount of product may thereby be shipped in the same containers as if traditional pallets are used. However, since the products are divided into quarters, each quarter is individually wrapped, and each quarter is supported by an individual subpallet, subdivision is facilitated.

Master pallets 15, 17 may also be assembled by positioning unstacked subpallets 12, 14 or 12, 14, 12′, 14′, as described above and inserting the plate 34. Then the master pallets 15, 17 may be stacked and the products wrapped in plastic, if desired.

After shipment to a warehouse, for example, the entire master pallet 15, 17 may be unloaded and stored by a forklift 26 or a handlift, as is a typical pallet. If the warehouse stores products for a store that only wants to display or unpack less than a full pallet, such as one quarter of the products typically supported on a pallet, or if the warehouse stores products for subsequent shipment to a customer that wants less than a full pallet, such as one quarter of the products typically supported on a pallet, one subpallet and the products supported on the one subpallet may be readily removed from the master pallet. The plastic wrap 39 around the entire master pallet 15, 17 may be opened or cut and one subpallet may be removed by the forklift 36 by engaging the space in one subpallet by one or more forklift blades 38 and moving the subpallet laterally away from the adjacent subpallet. Two or three subpallets may be similarly removed from the four unit master pallet 17, if desired, as well.

In the example of FIG. 8, the subpallet 14 and the products P stacked upon it can be separated from the four unit master pallet 17 by removing the plastic wrap 39, if present, and moving the subpallet 14 to the right along arrow A by the forklift 26 or handlift, to separate it from the connecting plate 34 and the adjacent subpallets 12, 12′, and 14′. Since the products stacked on the subpallet 14 is also wrapped in plastic wrap W, the subpallet 14 and the stacked products may be easily moved and shipped, if desired, without rewrapping. If both pallets 12′, 14′ are desired, they may be removed together by the forklift 26 or handlift. If the product on the pallet 12 is desired, it may be removed by being moved to the left along arrow B in FIG. 8, by the forklift 26 or handlift.

Alternatively, subpallets 12, 12′, 14, 14′ may be disconnected by removing the connecting plate 34 by pulling the rope 35 at one end of the plate. The forklift 26 or handlift can then lift a desired subpallet and carry it away.

A master pallet 15, 17 may comprise subpallets stacked with the same products, or different products P, as shown in FIG. 10. If a customer wants four subpallets, each supporting a different product, for example, four unit master pallets 17 in a warehouse, each supporting a different product, may be separated, rearranged, and connected to form a new four unit master pallet 17, supporting the four different types of products P. The new master pallet 17 may then be rewrapped, if desired, and shipped to the customer. A four unit master pallet 17 could be created to support two or three different types of products, as well.

In one example, each subpallet 12, 14 may be 56.50 cm long (L), 46 cm wide (W), and from about 3 inches to about 4 inches (from about 7.62 cm to about 10.16 cm) thick (T), as indicated in FIG. 1. The connecting plate 46 may be 92 cm long, 7 cm wide, and 0.8 cm thick, to connect four subpallets, to form a four unit master pallet 17, for example. A master pallet 17 comprising four interlocked subpallets 12, 14, 12′, 14′ in this example may be 92 cm long (L2) and 113 cm wide (W). These dimensions are appropriate for stacking packages of pneumatic fasteners, bulk fasteners, and packaged fasteners, for example. The four unit master pallet 17 of these dimensions described and comprising appropriate materials of the materials described above can support from about 1,800 pounds (816 kg) to about 3,300 pounds (1,498 kg). Each subpallet can individually support at least about one quarter as much.

While in the embodiment described above, the upper and lower surfaces of the subpallets 12, 14, 12′, 14′ comprise plates 16, 18, respectively, either or both of the upper and lower surfaces may comprise a plurality of boards 38 of any of the materials described above, separated by spaces 39, as shown in FIG. 11.

Master pallets of any desired size may be made. For example, subpallets and the resulting master pallet for other types of products may have different dimensions. A larger connecting plate 34 may be used for heavier products or larger pallets. Also, additional pallets may be coupled together to form larger master pallets, such as 6 unit master pallets or larger, by providing a longer connecting plate 34 to connect additional pairs of subpallets. In addition, a subpallet 12 may have grooves 34 on both blocks 20, 22, to enable connection of subpallets on both sides of the subpallet 12 by additional connecting plates 34, as shown in FIG. 12. Providing grooves 32 on both blocks 20, 22 could also facilitate the positioning of the subpallets to form the two unit master pallet 15 and the four unit master pallet 17, by avoiding the need to rotate a subpallet (subpallet 14, for example), so that the one groove 34 faces a groove of an adjacent subpallet (subpallet 12, for example).

FIG. 13 is a side view of U-shaped or C-shaped clamp 40 of metal or plastic, which may be snapped over the adjacent blocks 20, 22 in two subpallets, such as subpallets 12, 14, as shown in FIG. 14. The clamp 40 has two arms 40a, 40, each of which may extend into the spaces 24 of adjacent subpallets 12, 14, and bear against inner surfaces 22a of the blocks 22. In a two unit master pallet, a clamp 40 may be provided on both sides of the subpallets 12, 14. Instead of entering the spaces 24, holes may be provided in the blocks 20 to receive the arms 40a, 40b of the clamp 40. The clamp 40 may be used in addition to or instead of the connecting plate 34 and groove 32. The clamp 40 may need to be removed by a screwdriver or other such device.

A four unit master pallet may be secured by clamps along with or instead of the connecting plate 34, by providing openings 42 in the blocks 20, 22, to receive additional clamps 40, as shown in FIG. 15.

In another variation, clamps or sleeves 50 may be fit tightly over portions of the top surface of the plate 16 and the bottom surface of the plate 18 of adjacent subpallets 12, 14, 12′, 14′, as shown in FIGS. 16 and 17. A side view of a sleeve is shown in FIG. 16. Protrusions 50a (shown in phantom) may be provided at the ends of the sleeve 50 to engage openings or grooves in the plate surfaces (not shown) so that the sleeves 50 may be snap fit onto the plates. The sleeve 50 may need to be removed by a screwdriver or other such device. As above, such sleeves may be provided instead of or along with the connecting plate 34.

Other connecting mechanisms may be used, as well. For example, the connecting member may be a plurality of rods that are inserted into aligned grooves or openings through the blocks 20, 22, in a snug fit.

Changes may be made to the embodiments described herein without departing from the spirit and scope of the invention, which is defined by the claims, below.

Claims

1. A pallet comprising: a first pallet comprising a first side wall, the first side wall having a length and a first groove lying in a plane and extending along the entire length;a second pallet comprising a second side wall adjacent to the first side wall, the second side wall having a second length and a second groove lying in the plane and extending along the entire second length, the second groove facing the first groove and being aligned with the first groove in the plane, along the entire first and second lengths; anda connecting member within the aligned first and second grooves to connect the first and second pallets to each other.

2. The pallet of claim 1, wherein the plane is a horizontal plane.

3. The pallet of claim 2, wherein the connecting member comprises a horizontally extending plate.

4. The pallet of claim 3, wherein the horizontally extending member comprises a single flat plate.

5. The pallet of claim 4, wherein the single flat plate has the same length as the first and second lengths.

6. The pallet of claim 3, further comprising a member coupled to the plate and extending out of the groove.

7. The pallet of claim 6, wherein the member comprises a string or rope.

8. The pallet of claim 1, further comprising: a third pallet comprising a third side wall, the third side wall having a third length and a third groove lying in the plane and extending along the entire third length; anda fourth pallet comprising a fourth side wall adjacent to the third side wall, the fourth side wall having a fourth length and a fourth groove lying in the plane and extending along the entire fourth length, the third groove facing the fourth groove and being aligned with the fourth groove along the third and fourth lengths; andthe third and fourth pallets being adjacent to the first and second pallets such that the first and third grooves and the second and fourth grooves are aligned in the same plane;wherein the connecting member is within the aligned first, second, third, and fourth grooves, to connect the first, second, third, and fourth pallets.

9. The pallet of claim 8, wherein the plane is horizontal.

10. The pallet of claim 8, further comprising: a clamp securing adjacent pallets together.

11. The pallet of claim 1, wherein the first and second pallets comprise: first and second respective upper surfaces, to support objects, the first and second upper surfaces being coupled to the first and second side walls, respectively;third and fourth respective side walls opposite the first and second side respective walls, the third and fourth side walls being coupled to the first and second upper surfaces, respectively;wherein the first and second side walls and the third and fourth side walls define respective spaces to receive a respective fork of a forklift or handlift.

12. The pallet of claim 11, further comprising: first and second respective lower surfaces opposing the upper surfaces, the lower surfaces being coupled to the first and second side walls, respectively.

13. The pallet of claim 11, wherein the first and second upper surfaces each comprise a plurality of surfaces.

14. The pallet of claim 12, wherein the first and second lower surfaces each comprise a plurality of surfaces.

15. The pallet of claim 1, wherein the first and second side walls are compressible by the weight of sufficient objects on the respective pallet, to bear against the connecting member.

16. A pallet comprising: a first pallet comprising a first side wall, the side wall having a first horizontal groove extending at least half way along the side wall;a second pallet comprising a second side wall adjacent to the first side wall, the second side wall having a second horizontal groove extending at least half way along the second side wall, the second groove facing the first groove and being aligned with the first groove, anda single flat plate within the aligned first and second grooves to connect the first and second pallets, the plate having a length extending at least half way along either or both of the first and second walls.

17. The pallet of claim 16, further comprising: a third pallet comprising a third side wall, the third side wall having a third groove lying in the plane and extending along the entire third side wall; anda fourth pallet comprising a fourth side wall adjacent to the third side wall, the fourth side wall having a fourth groove lying in the plane and extending along the entire fourth side wall, the third groove facing the fourth groove and being aligned with the fourth groove along the third and fourth side walls; andthe third and fourth pallets being adjacent to the first and second pallets such that the first and third grooves and the second and fourth grooves are aligned in the same plane;the connecting member being within the aligned first, second, third, and fourth grooves to connect the first, second, third, and fourth pallets.

18. A method of using a pallet comprising: positioning a first pallet comprising a first side wall having a first groove extending at least halfway along the first side wall with a second pallet comprising a second side wall having a second groove extending at least halfway along the second side wall, to align the first and second grooves;inserting a connecting member into the aligned first and second grooves, at least halfway along either or both of the first and second side walls to connect the first pallet to the second pallet; andmoving the connected first and second pallets to a second location.

19. The method of claim 18, further comprising: loading at least the first pallet with a load, prior to positioning the first and second pallets.

20. The method of claim 19, further comprising securing the first load to the first pallet.

21. The method of claim 19, further comprising wrapping the load on the first pallet with plastic.

22. The method of claim 18, further comprising: positioning a third pallet comprising a third side wall having a third groove and a fourth pallet comprising a fourth side wall having a fourth groove with respect to the first and second pallets such that the third and fourth side walls are adjacent, the third groove and the fourth groove are aligned with each other, and the third and fourth grooves are aligned with the first and second grooves; andinserting the connecting member into the aligned third, fourth, first, and second grooves.

23. The method of claim 18, further comprising: loading the first pallet with a first load;loading the second pallet with a second load; andwrapping the secured first and second loads to each other with plastic.

24. The method of claim 18, further comprising: removing the connecting member at the second location; andmoving the first pallet to a third location.

25. The method of claim 18, further comprising: loading the first pallet with a first load comprising a first product; andloading the second pallet with a second load comprising a second product different than the first product.