AU2004281850B2 - A pallet - Google Patents

Description

WO 2005/037667 PCT/AU2004/001397 A PALLET Field of the Invention The present invention relates to pallets and in particular to a multi-purpose pallet having detachable components. 5 Background of the Invention Pallets made of wood are typically used throughout the world for easy storing and transporting of goods. These pallets are generally of a square shape having an upper and lower deck made of a series of wooden planks and at least two solid wooden beams therebetween. The pallet is normally nailed together and includes slots within which a 10 forklift's tines or other material handling devices can be located for lifting and moving the pallet. Known pallets suffer from many disadvantages. For example; they are expensive to manufacture; require repeated repair; are limited to standard sizes; have protruding fixings or connections; are limited in the amount they can carry; are easy to 15 damage or break; are heavy; difficult to attach additional components when required; absorb moisture, liquids and odours; are a fire risk; can have termite and insect contamination; splinter easily; the nails can loosen; have a short life span and the timber used is generally from hardwood forests. Of particular concern is that wood pallets damaged easily and the repair or replacement of the pallet is expensive, time consuming 20 and it is usually easier to just discard the pallet. Further, wood pallets retain dirt and other undesirable substances which minimises their use in contamination or hygienic areas such as the food or medical industries. Metal and plastic pallets have also been developed. These types of pallets have many disadvantages similar to wood pallets. 25 Accordingly, there is a need for a lightweight metal pallet that has releasably connectable parts for easy maintenance and repair, overcomes debris and contamination problems and includes no sharp edges. Object of the Invention It is an object of the present invention to overcome or ameliorate some of the 30 disadvantages of the prior art, or at least to provide a useful alternative.

2 Summary of the Invention There is firstly disclosed herein a metal pallet having: a top deck of sheet metal; a bottom deck of sheet metal spaced from the top deck; s at least two longitudinally elongated bearers each formed of sheet metal and secured to and extending transversely between the decks so that the top deck is supported on the bottom deck; and wherein each bearer has a first and a second longitudinally extending bearer portion, with each portion being secured to said decks and extending separately transversely between 1o said decks and wherein each portion has a longitudinally extending top web secured to the top deck, a longitudinally extending bottom web secured to the bottom deck, a longitudinally extending central web extending generally normal to said decks, and longitudinally extending inclined web portions securing the central web to the top and bottom webs, each inclined web portion being inclined to the decks by an acute angle. 15 Preferably, said central webs of said first and second portions are releasably securable together. Preferably, said top and bottom webs are releasably securable to said decks. Preferably, said webs are releasably securable to at least one of said decks and each other by fastening means. 20 Preferably, said fastening means are threaded fasteners as rivets. Preferably, said pallet includes a plurality of holes for receiving each said fastening means. Preferably, said pallet is of a generally rectangular configuration having a front edge, a rear edge and two side edges, wherein at least one edge includes a cover plate; at 25 least one elongate bearer includes a stiffener; at least one bearer includes an end cap; and at least one of said top and said bottom deck is of a profiled configuration. Preferably, said profiled configuration are corrugations. Preferably, said pallet includes a sheet material secured to at least one said deck. Preferably, said pallet includes cavities for receipt of tines of a forklift or other 30 handling equipment. Preferably, said cavities are located on all sides of said pallet.

2a In a second aspect of the invention there is preferably provided a detachable component metal pallet comprising: a sheet metal top deck; a sheet metal bottom deck spaced apart from and generally parallel to the top 5 deck; at least two elongate bearers, wherein the elongate bearers are positioned between the top and bottom decks such that they extend lengthwise parallel to the top and bottom decks, each elongate bearer comprising a first and a second portion extending lengthwise parallel to the top and bottom decks, where each first and second portion has a 1o top web, a central web and a bottom web, and inclined portions connect the top web to the central web and the central web to the bottom web, where the inclined portions aligned to the top and bottom decks at an acute angle; wherein the first and second portions of the elongate bearers are aligned such that the central webs of each first and second portion abut each other and are oriented is perpendicularly to the top and bottom decks, the central webs being releasably securable to each other via at least one fastener; wherein the top and bottom webs of the first and second portions are oriented generally parallel to the top and bottom decks, the top webs abutting and being releasably securable to the top deck via at least one fastener and the bottom webs abutting and being 20 releasably securable to the bottom deck via at least one fastener, such that the top and bottom decks are releasably secured together and the top deck is supported on the bottom deck via the elongate bearers; and wherein the top deck, the bottom deck and the first and second portions are all configured to be able to be detached and replaced by replacement components. 25 Brief Description of the Drawings A preferred form of the present invention will now be described, by way of example only, with reference to the accompanying drawings wherein: WO 2005/037667 PCT/AU2004/001397 3 Figure 1 is a partial perspective view of a bearer for a pallet of an embodiment of the present invention; Figure 2 is a perspective view of a pallet of an embodiment of the present invention; 5 Figure 3 is a partial perspective view of the pallet of Figure 2 with attachments; Figure 4 is a partial side view of the pallet of Figure 2 with attachments. Figures 5a to 5d are cross-sectional views of bearer embodiments for a pallet of the present invention; Figures 6a to 6c are partial side views of embodiments of the invention showing 10 recesses for tines of a forklift; Figures 7a and 7b are perspective views showing the four way openings of Figs. 6a to 6c; and Figure 8 shows a cross-sectional view of an alternate embodiment of the pallet of Fig. 1. 15 Detailed Description of the Preferred Embodiments There is disclosed herein a pallet 1 manufactured of metal typically galvanised steel or aluminium. The pallet 1 includes a top deck 5, a bottom deck 10 and at least two elongate bearers 15 securing the decks 5, 10 together. As best seen in Figures 1, 5a to 5d and 8 each bearer 15 has a first portion 16 and a second portion 17 extending separately 20 between the decks 5, 10 and having a top web 20 and a bottom web 25 connected to a central web 30 by inclined portions 35. In use, the webs 20, 25, 30 of the first and second portions 16, 17 are releasably securable to each other and the decks 5, 10 by fastening means 40 such as a threaded fastener which is typically located in holes 45. In the preferred forn the central webs 30 are substantially vertical or normal to the decks 5, 10. 25 Alternatively, the fastening means 40 could be a weld or rivet, the pallet 1 easily being repaired by drilling out the weld or rivet, replacing the part and re-welding or riveting. Typically, the portions 16, 17 of the bearers 15 are positioned abutting each other and fastening means 40 in the form of a threaded fastener, spot welds, blind rivet or the like secure the two central webs 30 together. The pallet 1 can also include a counter-sunk 30 bore or aperture in the holes 45 for hiding the fastening means 40 below the plane of the adjacent surfaces. This will ensure no sharp objects, such as the end of a bolt, protrude above the adjacent surface of the deck 5, 10. As best seen in Figure 3, the elongate bearer 15 can also include a stiffener strip 50 to provide further support to the bearer 15 when the pallet 1 is required for heavy loads. The stiffener strip 50 is merely attached along the WO 2005/037667 PCT/AU2004/001397 4 central web 30 at the holes 45 for the fastening means 40. The pallet 1 can also include many additional components to provide a more profiled pallet 1. For example, the top or bottom decks 5, 10 can include profiled configurations such as corrugations as best seen in Figures 2 and 7a, 7b. Cover plates and end caps 55 or the like as seen in Figures 3 and 5 4 could also be utilised. Referring specifically to Figures 1, 5a to 5c and 8, the top and bottom webs 20, 25 are load support flanges providing an opening 47 therebetween allowing access for spot welding or attaching threaded fasteners such as screws or bolts or the like. The separator of the portions 16, 17 also allows for only one side of the bearer 15 to be 10 replaced if required. In a preferred form, the webs 20, 25 are abutting. A rounded non sharp edge is preferably provided between the webs 20, 25 and inclined portions 35. The overall dimensions of all components can change depending upon the required pallet 1. In Figure 2 a standard 1000 x 1200 cm pallet 1 is shown. The pallet 1 dimensions can vary to suit particular industry requirements such as, 1165 x 1165 cm, for 15 example. The decks 5, 10 can be in varying configurations, such as corrugations, flat panels, curves or the like. The corrugations for example, can be in any direction, non uniform, and/or a combination of directions or shapes depending on the load to be lifted and moved. In the embodiment shown, galvanised steel corrugations are shown providing superior strength and durability. The corrugations also provide maximum 20 surface contact while retaining structural adequacy. However, a 100% flat surface 79 can be provided in place of the corrugations or affixed to the top of the corrugations (see Figure 4) or a combination of surfaces can be provided. The advantages of the pallet 1 as shown herein is that all components can be disassembled and reassembled or damaged components easily replaced, if required. 25 Shaped sleeves 60 (as best seen in Figure 4) made of any material could also be added to cover edges and increase strength. End caps 55 could also be added to provide a more aesthetically looking pallet 1, provide impact resistance, cover apertures and edges at the ends of the bearers 15. If corrugations are used an edge strip 65 could also be provided to seal in any openings for hygiene requirements. There is also shown in Figures 2, 6a to 6c, 30 7a and 7b, openings 75 for the tines or wheels of forklifts and pallet trucks. The pallet 1 could also include a cross member (not shown) between the bearers 15 or inside the corrugations to provide additional support for very heavy loads. Figure 4 also shows additional componentary including a lip 77 formed in the corrugations to ensure no sharp edges and to stiffen against impact from a forklift. A 35 separate U-shaped cover 60 could also be provided as mentioned above. The lip 77 also WO 2005/037667 PCT/AU2004/001397 5 provides an increase in the horizontal strength of the pallet 1. This embodiment also shows a further sheet material 79 across the top of the corrugations and a stiffener strip 50. The sheet material 79 could be galvanised steel, timber, plastic or any other material, if required. 5 Figures 5a to 5d and 8 show different embodiments of the bearer 15. These embodiments are utilised for different fastener combinations allowing easy access to the bearer 15. As seen in Figures 5a and 5b additional members 80 can be included to receive the decks 5, 10. Figures 6a to 6c, 7a and 7b show further embodiments of the invention, detailing 10 openings 75 in the pallet 1 for allowing four way entry for a lifting device. Figure 8, shows a further embodiment of the invention having fastening means 40 in the form of a screw and rivet. The webs 20 and 25 are turned inward to reduce sharp edges. The pallet I disclosed herein can be completely disassembled as all components is can be replaced individually quickly and inexpensively. Pallet 1 has extremely strong load bearing capacity due to the angles of the members making up the portions 16, 17; has structural adequacy and load distribution for rotational movements; the shape can be altered in all dimensions and angles for various purposes; smooth non sharp surfaces on each bearer 15 horizontal side surfaces; small cross sectional area of end maximises width 20 of openings 75 for fork lift tines; allows for bolted, riveted, screwed or welded fixings 40 for joins and decks 5, 10 to bearers 15; holes or apertures 45 are recessed allowing for non protruding fixings/connections; external side has no visible joins, resists dirt collection; interior space is minimised to reduce contamination area; interior space small to enhance any cleaning pressure hose effect; the bearers 15 could be galvanised steel or 25 aluminium. The deck 5, 10 and the additional sheet material layer 79 could be steel, timber, plastic, paperboard, composites or fibres. The steel bearers 15 for example could support timber decking and be secured by a threaded nail, bolt or the like. The bearer 15 shape allows for mid height horizontal stiffener 50 attachment for extra heavy loads; bearer 30 shape can be segmented to allow for 4 way pallet option; deck 5, 10 can be adapted to 100% coverage if pallet 1 purpose requires; one or more additional decks 5, 10 could be added; allows hygienic adaptability for food industry requirements; deck board profile can have edge returns 77 roll formed to avoid sharp edges; deck board edge return 60 to stiffen end against fork lift and pallet truck impact; bearer 15 shape allows for timber 35 deck boards if necessary; deck board shape can have steel strip attached to cover cavities; WO 2005/037667 PCT/AU2004/001397 6 deck board profile can have 45-60 degree folded ends to eliminate sharp edges; and alternatively deck boards can have horizontal angle cover attachment. Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many 5 other forms and other structures.

Claims (17)

1. A metal pallet having: 5 a top deck of sheet metal; a bottom deck of sheet metal spaced from the top deck; at least two longitudinally elongated bearers each formed of sheet metal and secured to and extending transversely between the decks so that the top deck is supported on the bottom deck; and wherein 10 each bearer has a first and a second longitudinally extending bearer portion, with each portion being secured to said decks and extending separately transversely between said decks and wherein each portion has a longitudinally extending top web secured to the top deck, a longitudinally extending bottom web secured to the bottom deck, a longitudinally extending central web extending generally normal to said decks, and is longitudinally extending inclined web portions securing the central web to the top and bottom webs, each inclined web portion being inclined to the decks by an acute angle.

2. The pallet according to claim 1, wherein said central webs of said first and second portions are releasably securable together. 20

3. The pallet according to claim 1, wherein said top and bottom webs are releasably securable to said decks.

4. The pallet according to claim 1, wherein said webs are releasably 25 securable to at least one of said decks and each other by fastening means.

5. The pallet according to claim 1, wherein said fastening means are threaded fasteners. 30

6. The pallet according to claim 4, wherein said pallet includes a plurality of holes for receiving each said fastening means.

7. The pallet according to claim 4, wherein said fastening means are rivets. 8

8. The pallet according to claim 1, wherein said pallet is of a generally rectangular configuration having a front edge, a rear edge and two side edges.

9. The pallet according to claim 8, wherein at least one edge includes a cover plate. 5

10. The pallet according to claim 1, wherein at least one elongate bearer includes a stiffener.

11. The pallet according to claim 1, wherein at least one bearer includes an 10 end cap.

12. The pallet according to claim 1, wherein at least one of said top and said bottom deck is of a profiled configuration. 15

13. The pallet according to claim 12, wherein said profiled configuration are corrugations.

14. The pallet according to claim 1, wherein said pallet includes a sheet material secured to at least one said deck. 20

15. The pallet according to claim 1, wherein said pallet includes cavities for receipt of tines of a forklift or other handling equipment.

16. The pallet according to claim 15, wherein said cavities are located on all 25 sides of said pallet.

17. A detachable-component metal pallet comprising: a sheet metal top deck; a sheet metal bottom deck spaced apart from and generally parallel to the top 30 deck; at least two elongate bearers, wherein the elongate bearers are positioned between the top and bottom decks such that they extend lengthwise parallel to the top and bottom decks, each elongate bearer comprising a first and a second portion extending lengthwise parallel to the top and bottom decks, where each first and second portion has a 35 top web, a central web and a bottom web, and inclined portions connect the top web to the 9 central web and the central web to the bottom web, where the inclined portions aligned to the top and bottom decks at an acute angle; wherein the first and second portions of the elongate bearers are aligned such that the central webs of each first and second portion abut each other and are oriented s perpendicularly to the top and bottom decks, the central webs being releasably securable to each other via at least one fastener; wherein the top and bottom webs of the first and second portions are oriented generally parallel to the top and bottom decks, the top webs abutting and being releasably securable to the top deck via at least one fastener and the bottom webs abutting and being 10 releasably securable to the bottom deck via at least one fastener, such that the top and bottom decks are releasably secured together and the top deck is supported on the bottom deck via the elongate bearers; and wherein the top deck, the bottom deck and the first and second portions are all configured to be able to be detached and replaced by replacement components. Dated 24 June, 2010 Steel Pallet Systems Pty Ltd Patent Attorneys for the Applicant/Nominated Person SPRUSON & FERGUSON