WING PALLET WITH PRODUCT SELF-CENTERING FEATURE

Abstract

A wing pallet with product self-centering feature having a top surface with a lower middle portion is provided. The pallet includes an upper portion having an upper surface that is slightly bowed downwardly in the middle portion and a lower portion that supports the upper portion. The upper surface can be slightly concave or have planar portions that are inclined downward from the outer sides or edges. The contour of the upper surface cause the trays stacked on the upper surface to lean toward the middle of the pallet. Two sets of stacked trays will lean toward each and have no gap formed at the top of the stacks.

Description

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

FIELD OF THE INVENTION

The present invention is generally directed to a pallet having a top support surface that is configured to facilitate centering of containers stacked on the pallet, and more particularly, to a pallet having a top surface that has a slightly concave contour with a middle portion that is lower than an outer portion near the edges of the pallet.

DESCRIPTION OF THE PRIOR ART

Typical wood or plastic pallets used today to transfer goods or other items have a relatively flat upper support surface. Some plastic pallets have an upper portion that is larger than a lower portion that supports the upper portion. The larger upper portion will have overhanging portions approximate its outer perimeter that extend outward past the footprint of the lower portion. These overhanging portions have a tendency to deflect downward (especially when a heavy product is placed on the upper surface of the pallet). This can affect the stability of items placed on the pallet. For example, columns of stacked trays (such as bakery trays or other similar containers or items) will have a propensity for forming a gap between the stacks as the stacks get higher. This creates an unstable and potentially dangerous condition which can result with one or more stacks tipping and falling during transport.

The present invention provides a pallet with a support surface configured to center stacks of containers on the pallet and avoid formation of gap between the stacks.

SUMMARY OF THE INVENTION

The present invention is generally directed to a wing pallet with a product self-centering feature in the form of a concave top surface. Specifically, a center or middle portion of an upper or top surface of the pallet is lower than the outer portions of the upper surface. This will cause a stack of trays to lean to the middle of the pallet and rest up to or against another stack.

In accordance with one aspect of the present invention a pallet with product self-centering feature comprises an upper support platform having a generally rectangular top support surface having a first side and an opposing second side, a first end perpendicular to the first side and the second side and a second opposing end perpendicular to the first side and the second side. A plurality of legs extend downward from the upper support platform. The first side of the top support surface of the upper support platform has a first height, the second side of the top support surface of the upper support platform has the first height, and a middle portion of the top support surface of the upper support platform approximately mid-way between the first side and the second side has a second height less than the first height. That is, the middle portion is lower than the side portions of the top support surface. For a 43.50 inch by 50 inch pallet, the middle portion can be approximately 0.18 inches lower than the first side and the second side.

The top support surface can be generally planar and can be inclined or slope downward from the first side to the middle portion. Similarly, the top surface can be generally planar and can be inclined or slope downward from the second side to the middle portion. Alternatively, the top support surface can have an upwardly concave shape from the first side to the second side with a lowest point proximate the middle portion.

The plurality of legs can include a first set of legs proximate the first side of the upper support platform, a second set of legs proximate the second side of the upper support platform and a third set of legs proximate the middle portion of the upper support platform. The third set of legs can have a height less than a height of the first set of legs and the second set of legs. A plurality of runners can extend between the plurality of legs.

The pallet can further comprise a first tray supported on the top surface of the upper support platform. The tray can extend from the first side of the upper support platform to the middle portion of the upper support platform. The pallet can also comprise a second tray supported on the top surface of the upper support platform. The second tray can extend from the second side of the upper support platform to the middle portion of the upper support platform. A portion of the first tray can contact or abut a portion of the second tray proximate the middle portion of the upper support panel. A first plurality of trays can be stacked on the first tray and a second plurality of trays can be stacked on the second tray. Each one of the first plurality of trays can contact or abut one of the second plurality of trays at the middle portion of the upper support panel. The trays can be bakery trays or other similar tray or container.

The pallet can be formed from a molded plastic. Other similar or suitable materials can also be used.

In accordance with another aspect of the invention, a plastic pallet with a self-centering structure for supporting a plurality of trays comprises an upper platform having a generally rectangular top support surface for supporting a plurality of trays, the top support surface having a middle portion lower than an outer portion of the top support surface. The pallet also includes a lower support structure for supporting the upper platform.

The top support surface can be generally planar and can be inclined or slope at a downward angle from a first side of the upper portion toward the middle portion of the top support surface. Similarly, the top support surface can be generally planar and can be inclined or slope at a downward angle from a second side of the upper portion toward the middle portion of the top support surface. Again, the top support surface can also have an upwardly concave contour with a lowest point proximate the middle portion.

The lower support structure can include a plurality of legs extending downward from the upper platform. The plurality of legs can include a first set of legs proximate the first side, a second set of legs proximate the second side and a third set of legs proximate the middle portion. The middle portion of the top support surface is approximately 0.18 inches lower than the outer portion of the top support surface. The legs can be sized to accommodate for the difference in height between the middle portion and the rest of the top support surface.

The top support surface is configured to require sets of trays stacked on the top surface to lean into or toward each other proximate the middle portion. This prevents a gap from forming between the stacks of trays—especially near the top of the stack.

The upper platform has a width and a length, and the lower support structure can have a width and a length less than the width and the length of the upper platform. This will provide an overhang of the upper platform over the lower support structure around the periphery of the upper platform.

A plurality of runners can extend between the plurality of legs and be connected thereto. The pallet can also include other typical features like ribs and channels and other similar structures associated with plastic pallets.

Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a wing pallet having an upper surface in accordance with the present invention;

FIG. 2 is a front side plan view of the pallet of FIG. 1

FIG. 3 is a front perspective view of a known pallet with stacks of trays forming a gap between the tops of the stacks;

FIG. 4 is a front side plan view of the pallet of FIG. 1 with a first tray and a second tray positioned next to each other on the upper surface of the pallet;

FIG. 5 is a front perspective view of the pallet of FIG. 1 with stacks of trays having no gaps between the stacks;

FIG. 6 is a perspective view of only the upper portion of the pallet of FIG. 1;

FIG. 7 is a perspective view of only the lower portion of the pallet of FIG. 1;

FIG. 8 is a side plan view of the pallet with a line under a lower surface of the upper portion showing the slight curvature of the upper portion; and,

FIG. 9 is an enlarged side plan view showing the gap between the abutting trays at the middle portion of the pallet.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

FIGS. 1, 2 and 4-9 show a wing pallet 10 having a top or upper surface 12 configured to center products (e.g., trays or other containers) stacked on the pallet 10. The pallet 10 has an upper portion 14 (see FIG. 6) that includes the upper surface 12, and a lower portion 16 (see FIG. 7) that supports the upper portion 14. Both portions 14, 16 can be formed from a molded plastic or other similar material. The portions 14, 16 can be snap fitted together or welded or otherwise connected.

The pallet 10 can be used to specifically transport stacks 18 of bakery trays 20. However, other trays, containers or goods can also be transported with the pallet 10.

The upper portion 14 of the pallet 10 is generally rectangular and is slightly larger than the lower portion 16. Accordingly, an outer portion of the upper portion 14 (including an outer portion of the top surface 12) extends outward over the lower portion 16 (i.e., this outer portion hangs over the lower portion 16). In prior pallets 22 having similar overhanging structure, the overhanging portion would tend to deflect downward (especially over time, and transporting heavy loads). This would result in stacks of trays on the pallet leaning outward-away from the middle of the pallet 22. This was evident in a gap 24 forming between the upper portions of two stacks of trays 20, such as that shown in FIG. 3. This precarious configuration is not stable and could result in potentially harmful and expensive tipping of the trays 22 and their contents.

The present pallet 10 prevents the “gap” formation between stacks of trays by providing the top surface 12 of the upper portion 14 with a generally concave shape where a middle portion 26 of the upper surface 12 is lower than the remaining portion of the top surface 12. This causes the stacks of trays 20 to lean toward the middle of the pallet 10 and contact each other—eliminating any gap as shown in FIG. 5.

As shown in FIG. 6, the upper portion 14 of the pallet 10 has a first side 28, an opposing second side 30, a third side 32 and an opposing fourth side 34 which define a generally rectangular upper surface 12. The first side 28 and second side 30 can be 43.50 inches, and the third side 32 and fourth side 34 can be 52.00 inches. The upper portion 14 can include a plurality of downwardly extending projections 36 that can be incorporated with legs 38 in the lower portion 16.

As shown in FIG. 7, the lower portion 16 includes a plurality of legs 38 connected by runners 40 of the lower portion 16. The legs 38 and runners 40 are designed to create fork tine openings for a forklift or other similar mechanisms. The bottom surface of the legs 38 and runners 40 is flat. The bottom portion includes a first side 42, an opposing second side 44, a third side 46 and an opposing fourth side 48. The first side 42 and second side 44 of the lower portion 16 can be 40.00 inches and the third side 46 and fourth side 48 can be 48.00 inches. Because the upper portion 14 is larger than the lower portion 16 (from side to side), it will have a slight overhang portion 50 (visible in the side views of FIGS. 2 and 4. The overhang 50 will extend around the entire periphery of the upper portion 14.

The upper surface 12 of the pallet 10 is designed to have a first height proximate the first side 28 and the second side 30, and to have a second height—lower than the first height—at the middle portion 26 of the pallet. The first height can be 6.72 inches (above the bottom surface of the lower portion 16) and the middle portion 26 can be 3/16 of an inch (0.1875 inches) lower than the first and second sides 28, 30. The upper surface 12 can be slightly concave (from first side 28 to second side 30) wherein the surface is inclined or slopes downward from the sides 28, 30 to the middle portion 26. Alternatively, the upper surface 12 can be two generally planar surfaces angled downward toward the middle portion 26 from each side 28, 30. The dip toward the middle portion 26 in the upper surface 12 can be accommodated by the thickness of the upper portion 14, or can be implemented with legs supporting the middle portion 26 being slightly shorter than legs supporting the sides 28, 30 of the pallet.

Referring initially to FIG. 4, two bakery trays 20 are shown positioned side by side on the upper surface 12 of the pallet 10. Each tray 20 is sized such that it extends from one of the sides 28, 30 of the pallet to the middle portion 26. The slight bowing of the upper surface 12 provides for a better load transfer of the trays 20 on the surface 12. Specifically, because of the contour of the upper surface 12, the trays 20 slightly lean toward each other and there is no visible gap between the two trays 20. As illustrated in FIG. 5, even when multiple trays 20 are stacked on each of the two bottom trays 20, there is no visible gap anywhere between the two stacks, including at the top 52 of the stacks.

FIG. 8 is a slightly enlarged side view of the pallet 10 and includes a bold line 54 drawn below a lower surface 56 of the upper portion 14. The line 54 illustrates the gradual curvature of the upper portion 14 (which results in the curvature of the upper surface 12).

FIG. 9 is an enlarged view of the middle portion 26 of the pallet 10 with two trays 20 positioned on the upper surface 12. As shown, the end walls of the trays 20 abut each other proximate the middle portion 26 of the pallet 10 and leave a 0.18 inch gap 60 between the abutting ends 58 of the trays 20 and the upper surface 12.

The pallet 10 is formed from a molded plastic. The pallet can be a twin sheet thermoformed solution. As evident in the Figures, the pallet 10 can include channels, ribs and other typical features associated with plastic pallets.

Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.

Claims

1. A pallet with product self-centering feature comprising: an upper support platform having a generally rectangular top support surface having a first side and an opposing second side, a first end perpendicular to the first side and the second side and a second opposing end perpendicular to the first side and the second side;a plurality of legs extending downward from the upper support platform; and,wherein the first side of the upper support platform has a first height, the second side of the upper support platform has the first height, and a middle portion of the upper support platform approximately mid-way between the first side and the second side has a second height less than the first height.

2. The pallet of claim 1 wherein the top surface slopes downward from the first side to the middle portion.

3. The pallet of claim 2 wherein the top surface slopes downward from the second side to the middle portion.

4. The pallet of claim 1 wherein the top surface has an upwardly concave contour.

5. The pallet of claim 1 wherein the plurality of legs includes a first set of legs proximate the first side of the upper support platform, a second set of legs proximate the second side of the upper support platform and a third set of legs proximate the middle portion of the upper support platform, wherein the third set of legs are smaller than the first set of legs and the second set of legs.

6. The pallet of claim 3 further comprising a plurality of runners extending between the plurality of legs.

7. The pallet of claim 1 further comprising a first tray supported on the top surface of the upper support platform and extending from the first side of the upper support platform to the middle portion of the upper support platform, and a second tray supported on the top surface of the upper support platform and extending from the second side of the upper support platform to the middle portion of the upper support platform wherein a portion of the first tray contacts a portion of the second tray proximate the middle portion of the upper support panel.

8. The pallet of claim 7 further comprising a first plurality of trays stacked on the first tray and a second plurality of trays stacked on the second tray wherein each one of the first plurality of trays contacts one of the second plurality of trays at the middle portion of the upper support panel.

9. The pallet of claim 1 wherein the pallet is formed from a molded plastic.

10. The pallet of claim 7 wherein the middle portion is approximately 0.18 inches lower than the first side and the second side and forms a gap between the upper surface and first tray and the second tray.

11. A plastic pallet with a self-centering structure for supporting a plurality of trays comprising: an upper platform having a generally rectangular top support surface for supporting a plurality of trays, the top support surface having a middle portion lower than an outer portion of the top support surface; and,a lower support structure for supporting the upper platform.

12. The plastic pallet of claim 11 wherein the top support surface slopes at a downward angle from a first side of the upper portion toward the middle portion of the top support surface.

13. The plastic pallet of claim 12 wherein the top support surface slopes at a downward angle from a second side of the upper portion toward the middle portion of the top support surface.

14. The plastic pallet of claim 11 wherein the top support surface has an upwardly concave shape.

15. The plastic pallet of claim 13 wherein the lower support structure includes a plurality of legs extending downward from the upper platform.

16. The plastic pallet of claim 14 wherein the plurality of legs includes a first set of legs proximate the first side, a second set of legs proximate the second side and a third set of legs proximate the middle portion.

17. The plastic pallet of claim 11 wherein the middle portion of the top support surface is approximately 0.18 inches lower than the outer portion of the top support surface.

18. The plastic pallet of claim 11 wherein the top support surface is configured to require sets of trays stacked on the top surface to lean into each other proximate the middle portion.

19. The plastic pallet of claim 11 wherein the upper platform has a width and a length, and the lower support structure has a width and a length less than the width and the length of the upper platform.

20. The plastic pallet of claim 14 further comprising a plurality of runners extending between the plurality of legs.