AU2018201130A1 - Pallet base, pallet base cleat and method of arranging pallet bases - Google Patents

Abstract

A pallet base cleat and pallet bases for storing and/or transporting objects is provided. The pallet base comprises a plurality of rails held parallel by a plurality of base cleats. Each base cleat comprises a body, a rail engaging means, and a base formation engaged in use with a base supporting formation of a second base cleat. When the base formation of the base cleat is engaged, in use, with a base supporting formation of a second said base cleat, at least one clearance space is defined between a first surface on the first side of the base cleat and a second surface on the second side of the second base cleat, the at least one clearance space being shaped and configured to allow at least one rail to pass therethrough. The base cleats may therefore be stacked in a staggered formation which may be particularly compact and may allow for economical transportation of the pallets when empty. 1 p2 Figure 1 Figure 1A

Description

PALLET BASE, PALLET BASE CLEAT AND METHOD OF ARRANGING PALLET BASES

TECHNICAL FIELD

The invention relates to a pallet base cleats and to pallet bases for carrying elongate objects such as, but not exclusively, aluminium extrusions, steel extrusions, pipes and the like.

BACKGROUND ART

Pallets are commonly used for storing and/or transporting products. Generally, the pallets include a platform, which can be solid or can be formed from 2 or more rails which support the product. Each pallet is normally constructed so that a fork lift or similar lifting mechanism can engage with the pallet so that the pallet, and contents, can be lifted for shifting (e.g. in a warehouse or factory) and for loading onto a vehicle for transportation.

One form of pallet used for storing and transporting preformed components for construction, such as doors, window frames etc., is formed by two elongate members (referred to hereinafter as “rails”) which are held parallel to one another a number of base members, known as “base cleats”. The base cleats and rails form a base for the pallet. A pallet base of this type typically comprises two base cleats located in the vicinity of the ends of the rails, with a number of further base cleats provided between the two. The number of additional cleats used depends on the length of the rails.

The pallet base described above can provide a stable platform for objects to be carried, and in many embodiments the pallet base may form the entire pallet (that is, a pallet may simply consist of a pallet base, with no additional components). However, in some other forms of pallet side members are attached to some or all of the base cleats. In use, these side members are located in an upright orientation (with respect to the base), at least at or near each end of the pallet base: the side members form sides for the pallet which can aid in holding the objects on the pallet.

The pallet structure is often completed by attaching a top member to the distal ends of two opposed side members to form, along with the base cleat and the side members, a rectangular holding structure. The top members provide additional strength to the structure, as well as providing a barrier to prevent objects on the pallet from raising up past the tops of the side members. The top member can also prevent the objects on the pallet from being crushed when another pallet is stacked on top of the first one as the weight of the second pallet is transferred to the side members. The side members may also be referred to as “side cleats” and the top cross member as a “top cleat”.

In many pallets it is common for wood to be used for the side and top cleats. In such cases the pallet may be made to order. The length of the rails is determined, the base members located into place and the wood cut to length as required to form the side and top cleats and the pallet. Each of these aspects can vary depending on the load to be carried on the pallet. In some other pallets the side and top cleats may be formed from elongate blocks of aluminium, steel or other suitable material.

In basic pallets a wooden top cleat can be nailed to the top ends of the wooden side cleats. Undoing the top cleat can lead to it being damaged (split, broken etc.) which can render the top cleat and/or the side cleats unsuitable for reuse. This can make it uneconomical to return the removed cleats to the manufacturer for recycling. In addition, the pallets bases may be relatively bulky and so it may be inconvenient and/or uneconomic to transport the pallet bases and/or the side and top cleats back to their source. This may lead to the some or all of the components of the pallet being scrapped rather than reused or recycled.

Some base cleats of the prior art comprise a plurality of channels configured to allow the rails to pass through the base cleat. In this manner the base cleats can be slid over the ends of the rails and along the rails into the desired location.

Sliding the base cleats along the rails can be inconvenient, especially if a base cleat which has been placed away from the ends of the rails is damaged or requires maintenance. In such cases all of the base cleats between the damaged one and the end must be removed before the damaged base cleat can be removed. Reassembly can also be time consuming and inconvenient as each of the removed base cleats needs to be slid along the rails into position. This can add to the labour costs of repairing a damaged pallet or pallet base.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of “including, but not limited to”.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF THE INVENTION

According to one aspect of the invention there is provided a base cleat for a pallet, the base cleat comprising a body provided with a plurality of rail engaging means, each rail engaging means adapted to engage an elongate rail having a pre-defined transverse cross-sectional shape, the base cleat further comprising a base formation provided on a first side of the base cleat and a base supporting formation provided on a second side of the base cleat opposite the first side, wherein each base formation is shaped and configured such that when the base formation of the base cleat is engaged, in use, with a base supporting formation of a second said base cleat, at least one clearance space is defined between a first surface on the first side of the base cleat and a second surface on the second side of the second base cleat, the at least one clearance space being shaped and configured to allow at least one rail having the predefined cross-sectional shape to pass therethrough.

Preferably the base cleat is adapted to engage two rails and to hold the rails in a spaced apart, parallel relationship.

Preferably the base formation comprises two spaced apart base formation members.

Preferably each base formation member defines a clearance space.

Preferably the base formation members are shaped and configured such that when the base formation of the base cleat is engaged, in use, with the base supporting formation of a second base cleat, the clearance space defined between the first surface of the base cleat and the second surface of the second base cleat is shaped and configured to allow two rails which are engaged with a third said base cleat to pass therethrough.

Preferably each base formation member defines a portion of a respective rail engaging means.

Preferably each base formation is removably connectable to the body.

Preferably the base cleat comprises at least one, and preferably two, side cleat engaging means.

Preferably each side cleat engaging means comprises a channel or pocket.

Preferably the base cleat comprises at least one aperture in the second surface, the at least one aperture adapted to engage an upper cleat member.

According to a second aspect of the invention there is provided a pallet comprising a plurality of rails engaged with a plurality of base cleats according to the first aspect of the invention.

According to a third aspect of the invention there is provided a kit of parts for a pallet base, the kit comprising at least two base cleats of the first aspect and at least two rails, wherein each rail has the predefined cross-section.

Preferably the kit comprises a top cleat and at least one of the base cleats comprises an aperture in the second surface which is adapted to engage the top cleat.

According to a fourth aspect of the present invention there is provided a method of arranging at least three pallet bases for transport, each pallet base comprising a plurality of base cleats of the first aspect of the invention engaged with a plurality of rails having the predefined crosssection, the method comprising the steps of: i) placing a first of the pallet bases on top of a second of the pallet bases such that the first pallet base is longitudinally offset relative to the second pallet base by a distance which is greater than a width of the base cleats; ii) placing a third of the pallet bases on top of the first and second pallet bases, wherein the base formations of at least two of the base cleats of the third pallet base are supported by the base supporting formations of the base cleats of the second pallet base.

According to a further aspect of the present invention there is provided a base cleat for a pallet base substantially as herein described with reference to the accompanying figures.

According to a still further aspect of the present invention there is provided a method of arranging at least three pallet bases for transport substantially as herein described with reference to Figures 4 and 5.

BRIEF DESCRIPTION OF DRAWINGS

Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which:

Figure 1 Is a perspective view of a pallet base according to one embodiment of the invention.

Figure 1A is an enlarged view of area A of Figure 1 showing a base cleat and a storage means for storing side cleats and top cleats.

Figure 2 Is a perspective view of a base cleat according to one embodiment of the invention.

Figure 3 is a side view of the base cleat of Figure 2.

Figure 4 is a side view of a stack of pallet bases of the present invention.

Figure 5 is a cross-section end view through plane R-R.

Figure 6 is a partially exploded side view of the base cleat of Figure 2.

BEST MODES FOR CARRYING OUT THE INVENTION

Referring first to Figures 1 and 1A a pallet base according to one embodiment of the invention is generally referenced by arrow 100. The pallet base 100 comprises a plurality of elongate base members (referred to herein as “rails”) 1 held in a substantially parallel, spaced apart relationship by a plurality of base cleats 101. In other, less preferred embodiments, the pallet base may comprise more or fewer than two rails.

Referring next to Figures 2 and 3, each base cleat 101 comprises a body 3 having a first surface 4 on a lower side of the body and a second surface 5 on an upper side of the body. Rail engaging means 6 are provided for engaging rails 1 having a predefined cross-sectional shape (for example a substantially rectangular shape) of pre-defined dimensions.

The first side of the base cleat 101 is provided with a base formation 7. In the embodiment shown, the base formation is provided as two downwardly depending base formation members 8.

The second surface 5 of the base cleat 101 is provided with a base supporting formation 9.

As best seen in Figures 4 and 5, the base formation 7 is shaped and configured such that when the base formation 7 of the base cleat 101 is engaged, in use, with a base supporting formation 9 of a second said base cleat 101 A, at least one clearance space 10 is defined between the first surface 4 on the first side of the base cleat 101 and the second surface 5A on the second side of the second base cleat 101 A, each clearance space 10 being shaped and configured to allow a rail 1 having the predefined cross-sectional shape to pass therethrough.

As can be seen in Figure 5, the base formation members 8 are preferably shaped and configured such that the clearance spaces 10 accommodate two rails 1 which are engaged with one or more further base cleats (and are therefore held at the same spacing as the rails engaged with the base cleat 101).

As mentioned above, each base cleat 101 is provided with a plurality of rail engaging means 6. In the embodiment shown, two rail engaging means 6 are provided, although in other embodiments more or fewer than two rail engaging means may be provided. The rail engaging means 6 may be provided as apertures through the body 3 of the base cleats 101, or more preferably as channel portions 11 in the body 3 which can be at least partially closed off by a respective base formation member 8, as best seen in Figure 6. Each base formation member 8 is preferably removably connectable to the body 3, for example by use of suitable fasteners such as screws (not shown). This allows the removal of a single base cleat 101 from a pallet base 100, for example in the case of damage to the base cleat 101, without the need for the base cleat 101 to be slid to the end of the rail 1 as would be necessary if the rail engaging means 6 was formed by a simple aperture in the body 3.

Referring back to Figures 4 and 5, it can be seen that pallet bases 100 which utilize base cleats of the present invention can be arranged into a particularly compact formation for transportation (when not in use carrying objects).

Because the base cleats 101 provide clearance spaces which can accommodate the rails of another pallet base, the pallet bases 100 can be stacked in a staggered formation, with the base cleats of each pallet base longitudinally offset from those of the pallet bases immediately above and below by at least the width of a base cleat 101.

To create such a staggered formation a first of the pallet bases is placed on top of a second of the pallet bases such that the first pallet base is longitudinally offset relative to the second pallet base by a distance which is greater than a width of the base cleats. A third pallet bases is then placed on top of the first and second pallet bases, wherein the base formations of at least two of the base cleats of the third pallet base are supported by the base supporting formations of the base cleats of the second pallet base. A fourth pallet base, if added to the stack, would be stacked such that the base formations of at least two of the base cleats of the fourth pallet base are supported by the base supporting formations of the base cleats of the first pallet base, and so on.

By allowing this configuration of stacking, a stack of three such pallet bases 100 arranged in this formation has a height substantially equal to only two times the height of a single base cleat 101.

Referring next to Figures 2 and 5 in particular, the base cleat 101 may be provided with side cleat engaging means 20. In preferred embodiments a side cleat engaging means 20 is provided at either end of the base cleat 101. In the embodiment shown the side cleat engaging means are provided as channels or pockets into which a side cleat 13 can be fitted. In this way the side cleats can be releasable engaged with the base cleat. When engaged with the side cleat engaging means 20, the side cleats 13 are preferably held in an upright position, most preferably substantially parallel to each other.

Referring next to Figures 1 and 1A, in some embodiments the pallet base 100 may also comprise a storage means 12 for storing side cleats 13 and top cleats 14. The storage means 12 may comprise a tray portion 15 and rail engaging portions 16. In preferred embodiments the rail engaging portions 16 may engage the rails in a “clip-fit”. The storage means 12 may be used to transport side and/or top cleats when a plurality of pallet bases 100 are stacked together for transportation, as shown in Figure 4. As can be seen in Figure 4, by staggering the position of the storage means 12 between adjacent pallet bases 100, the storage means 12 do not interfere with the compact stacking of the pallet bases 100, even when carrying side and top cleats.

Referring next to Figure 2, in some embodiments the base cleats 101 may be provided with top cleat engaging means 17. In the embodiments shown the top cleat engaging means 17 take the form of one or more apertures 18 in the upper or second surface 5 of the base cleat 101. These apertures 18 are shaped and configured to engage side cleat engaging portions 19 (best seen in Figure 1A) of the top cleats 14. Figure 1 shows an example of a base cleat 101B with two top cleats 14 engaged with its cleat engaging means 17.

Those skilled in the art will appreciate that the present invention provides a pallet base cleat which can be used to form a pallet base which can be stored in a particularly compact configuration for transportation when not in use, thereby encouraging recycling of the pallet base.

Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

Claims (15)

1. A base cleat for a pallet, the base cleat comprising: a body provided with a plurality of rail engaging means, each rail engaging means adapted to engage an elongate rail having a pre-defined transverse crosssectional shape; a base formation provided on a first side of the base cleat; and a base supporting formation provided on a second side of the base cleat opposite the first side; wherein each base formation is shaped and configured such that when the base formation of the base cleat is engaged, in use, with a base supporting formation of a second said base cleat, at least one clearance space is defined between a first surface on the first side of the base cleat and a second surface on the second side of the second base cleat, the at least one clearance space being shaped and configured to allow at least one rail having the predefined cross-sectional shape to pass therethrough.

2. A base cleat according to claim 1, wherein the base cleat is adapted to engage two rails and to hold the rails in a spaced apart, parallel relationship.

3. A base cleat according to either claim 1 or 2, wherein the base formation comprises two spaced apart base formation members.

4. A base cleat according to claim 3, wherein each base formation member defines a clearance space.

5. A base cleat according to claim 4, wherein the base formation members are shaped and configured such that when the base formation of the base cleat is engaged, in use, with the base supporting formation of a second base cleat, the clearance space defined between the first surface of the base cleat and the second surface of the second base cleat is shaped and configured to allow two rails which are engaged with a third said base cleat to pass therethrough.

6. A base cleat according to any one of claims 3 to 5, wherein each base formation member defines a portion of a respective rail engaging means.

7. A base cleat according to any one of claims 3 to 6, wherein each base formation is removably connectable to the body.

8. A base cleat according to any one of claims 1 to 7, wherein the base cleat comprises at least one, and preferably two, side cleat engaging means.

9. A base cleat according to claim 8, wherein each side cleat engaging means comprises a channel or pocket.

10. A base cleat according to any one of claims 1 to 9, wherein the base cleat comprises at least one aperture in the second surface, the at least one aperture adapted to engage an upper cleat member.

11. A pallet for use in transporting and/or storing objects, the pallet comprising a plurality of rails engaged with a plurality of base cleats according to any one of claims 1 to 10.

12. A kit of parts for a pallet base, the kit comprising at least two base cleats according to any one of claims 1 to 10, and at least two rails, wherein each rail has the predefined cross-section.

13. A kit according to claim 12, wherein the kit comprises a top cleat and at least one of the base cleats comprises an aperture in the second surface which is adapted to engage the top cleat.

14. A method of arranging at least three pallet bases for transport, each pallet base comprising a plurality of base cleats according to any one of claims 1 to 10, engaged with a plurality of rails having the predefined cross-section, the method comprising the steps of: 1. placing a first of the pallet bases on top of a second of the pallet bases such that the first pallet base is longitudinally offset relative to the second pallet base by a distance which is greater than a width of the base cleats; and 2. placing a third of the pallet bases on top of the first and second pallet bases, wherein the base formations of at least two of the base cleats of the third pallet base are supported by the base supporting formations of the base cleats of the second pallet base.

15. A base cleat for a pallet base substantially as herein described with reference to the accompanying figures.