This invention relates to a pallet. In particular, the invention relates to a modular pallet that can be assembled based on specific requirements and therefore will be described in this context. However, it should be appreciated that the modular pallet can be produced on mass for a single purpose.
Pallets are generally used to both store and transport goods. However, pallets can vary greatly from country to country and industry to industry. For example, there are US pallets, Euro Pallets and Australia pallets all of which have different dimensions. In standard wood pallets, there are two-way entry pallets, four-way entry pallets, no baseboard pallets, close bordered pallets, open bordered pallets. All of these types of wooden pallets are produced to suit certain industries due to their strength and loading characteristics.
In certain industries, wooden pallets cannot be used due to their permeability characteristics. Accordingly, steel and plastic pallets are often used in biologically sensitive industries such as the medical or food industries. Steel pallets are also used in industries for the carriage of very heavy items that would crush a wooden pallet such as the mining industry. Again, each of these pallets is produced to meet industry requirements.
Where a specific pallet is required to be produced for a specific use, there is a typically large set-up cost to manufacture the pallet. Further, there is often a training requirement for workers to learn how to manufacture new pallets. This makes the manufacture of pallets with specific requirements expensive compared to mass-produced pallets where economies of scale can be utilised.
It is an object of the invention to overcome and/or alleviate one or more of the above disadvantages and/or provide the consumer with a useful or commercial choice.
In one form, although not necessarily the one or only form, the invention resides in a modular pallet comprising:
Each of the beams is typically made of the same material. The beams may be made of any suitable material such as steel, composite fibre, plastic, or fibreglass. Preferably the beam is made from steel.
Each beam typically has a constant cross-sectional along its length. Normally, each beam has the same cross-section. The beam may be an I-beam, H-beam, C-beam or hollow rectangular beam. Preferably the beams are either C-beams or I-beams.
The beams are typically parallel to each other. Two of the beams are typically located adjacent sides of the pallet. Normally there are two, three, four or six beams. The beams may be horizontally spaced. The beams may also be vertically spaced.
The pallet segments may be made from any suitable material. However, normally, the pallet segments are made from plastic. Any suitable plastic may be used. Normally, the plastic used is polyethylene or polyurethane.
One or more segment channels may extend through each of the pallet segments. The segment channel may extend entirely through or partially through the pallet segments.
One or more segments may be connected to one or more beams. One or more end segments may be locked to the beams. The beam may be deformed to lock the end segment to the beam. The beam may have a tab that is deformed to lock the end segment to the beam. The beam may also be locked to other segments.
A brace may be located between two pallet segments. The brace may be in the form of a bracing plate. One or more bracing channels may extend through each brace.
Typically the brace is made from a material that has greater strength than the pallet segment. The brace may be made from plastic, composite fibre or steel. Normally the pallet is made from steel.
Each pallet segment may include a deck and a base which are interconnected by two sides. The deck and the base may also be interconnected by at least one intermediate member. The deck and the base may be interconnected by at least two intermediate members.
At least two apertures may be formed within a pallet segment. At least three apertures may be formed within the pallet segment. Typically all of the apertures are located between the deck and the base of the pallet segment.
Normally one or more C-shaped channels are located within each of the sides of a pallet segment. Preferably, one or more C-shaped channels are located through each of the intermediate members of a pallet segment.
The modular pallet normally has at least two end segments and two tine segments. The modular pallet typically has are at least two end segments, two tine segments and two infill segments.
The modular pallet may have a tine segment located between an infill segment and an end segment.
Typically, the end segment has an enclosed front face. Typically, the tine segment has tine opening extending between the two sides and bisecting the base.
The brace is substantially planar in shape and has slightly smaller outer dimensions than the pallets segments.
Typically the brace is formed from a deck and a base which are interconnected by two sides. Preferably the deck and the base are interconnected by at least one intermediate member. Preferably the deck and the base of the brace are interconnected by at least two intermediate members.
Normally, at least two apertures are formed within the brace. Preferably, at least three apertures are formed within the brace. Typically all of the apertures located through the brace are located between the deck and the base.
Typically, one or more C-shaped channels are located within each of the sides of the brace. Preferably, one or more C-shaped channels are located through each of the intermediate members of the brace.
In another form, the invention resides in a method of manufacturing a pallet, the method including the steps of:
The method may further include the steps of:
The method may further include the step of deforming one or more beams to lock the one or more beams to a pallet segment. The deformation of the beam may occur at a tab formed within the beam. The deformation of the beam may occur using a tool that applies a force to the beam. The tool may apply the force to the beam via or through the pallet segment.
The pallet segments are typically formed from plastic using a forming machine. The pallet segments may be injection moulded. The pallet segments may be located over the beams shortly after being removed from the forming machine.
Further features of the invention will become apparent from the detailed description below.
An embodiment of the invention will now be described with reference to the accompanying drawings in which:
The beams 20 provide structural strength for the pallet 10. Each of the four beams are of the same shape with each of the beams being C-shaped steel beams. Each beam 20 has a web 21 with two depending flanges 22. Tabs 23 are located along the web 21 and can be deformed to pivot the tab 23 outwardly from the web 21. The beams 20 are spaced apart and parallel to each other. However, they are orientated differently with
The six pallet segment 30 provide the platform on which goods are carried and stored. Each pallet segment 30 is integrally formed from injection moulded polypropylene. The six pallet segments are twin walled 31 being supported by both longitudinal reinforcement members 32 and lateral reinforcement members 33. Accordingly, each pallet segment 10 is relatively hollow and accordingly relatively lightweight. The six pallet segments include two end segments 40, two tine segments 50 and two infill segments 60.
Each end pallet segment 40, as shown in more detail
Each tine pallet segment 50, as shown in more detail
Each infill pallet segment 60, as shown in more detail
A brace 70, as shown in more detail
To construct the pallet 10, one of the end segments 40 is positioned so that the front face 47 is located adjacent the ground. The four beams 30 are then inserted into respective C-shaped channels 46 located within each of the sides 43 and each of the intermediate members 44. A brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the end segment 40 and recessed within the end segment 40.
A tine segment 50 is then located over the beams 20 with the beams 20 being located through each of the sides 53 and each of the intermediate members 54. The tine segment 50 is located adjacent the brace 70. The brace 70 is also recessed within the tine segment 50.
A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the tine segment 70 and recessed within the tine segment 70.
An infill segment 60 is then located over the beams 20 with the beams 20 being located through each of the sides 63 and each of the intermediate members 64. The infill segment 60 is located adjacent the brace 70. The brace 70 is also recessed within the infill segment 60.
A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is located adjacent the infill segment 60 and recessed within the infill segment 60.
A further infill segment 60 is then located over the beams 20 with the beams 20 being located through each of the sides 63 and each of the intermediate members 64. The infill segment 60 is located adjacent the brace 70. The brace 70 is also recessed within the infill segment 60.
A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is located adjacent the infill segment 60 and recessed within the infill segment 60.
A tine segment 50 is then located over the beams 20 with the beams 20 being located through each of the sides 53 and each of the intermediate members 54. The tine segment 50 is located adjacent the brace 70. The brace 70 is also recessed within the tine segment 50.
A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the tine segment 70 and recessed within the tine segment 70.
Finally, an end segment 40 is then located over the beams 20 with the beams 20 being located through each of the sides 43 and each of the intermediate members 44. The end segment 40 is located adjacent the brace 70. The brace 70 is also recessed within the end segment 50.
It should be noted that each of the segments 30 (i.e. end segments 40, tine segments 50 and infill segments 60) are located over the beams 20 whilst at a temperate that is substantially above ambient temperature. The elevated temperature of the segments 30 increases the size of the C-shaped channels 46, 56, 66. This simplifies the application of the segments 30 over the beams 20. Further, once the segments 30 cool, the size of the C-shaped channels 46, 56, 66 reduce to shrink fit the segments 30 onto the beams 20 this holding fast the segments to the beams 20.
An impact tool (not shown) is used to depress the tabs 23 along the beam 20. This is performed by locating the tool inside the apertures 45, 55, 65 of the segments 30 to a location along the beam 20 where a tab 23 is located. A force is applied to the tab 23 by the tool via a respective side 43, 53, 64 or intermediate member 44, 54, 64 which deforms the tab 23 outwardly with respect to the web 21. This located the tab 23 a respective longitudinal reinforcement member 32 to lock the beam 20 to the segment 30. This operation is performed when the segments 30 are at a temperature that is substantially above ambient temperature which either allows the segment 30 to spring back after contact with the tool, or to deform with the tab 23 further locking the tab 23 to the segment 30.
The pallet 10 provides a number of advantages. Various sized pallet segments 30 and beam 20 can be produced to cater for different sized pallets 10. However, many of the same segments 30 can be utilised by a multitude of pallets 10 allowing for reduced costs due to economies of scale. The beams 20, segments 30 and braces 70 can be made from different materials to suit specific requirements. For example, in medical environments, the beams 20, segments 30 and braces 70 can all be made of medical grade plastic.
In this specification, the terms “comprise”, “comprises”, “comprising” or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.
The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.
It should be appreciated that various other changes and modifications may be made to the embodiments described without departing from the spirit or scope of the invention.
Number | Date | Country | Kind |
---|---|---|---|
2022902959 | Oct 2022 | AU | national |
2033575 | Nov 2022 | NL | national |