GB2273695A

GB2273695A - Pallet

Info

Publication number: GB2273695A
Application number: GB9324215A
Authority: GB
Inventors: Toshinaga Urabe
Original assignee: Individual
Current assignee: Individual
Priority date: 1992-12-09
Filing date: 1993-11-25
Publication date: 1994-06-29
Anticipated expiration: 2013-11-25
Also published as: DE4341312A1; GB2273695B; GB9324215D0

Description

2273695 PALLET This invention relates to a pallet used to transport and

store articles; in detail, it relates to a pallet formed by using plywood laminates or particle boards.

Conventionally, as a pallet used to transport and store articles, are available a pallet which is built by combining a top deck formed with a corrugated board with supports made of paper tubes as given in such documents as the Patent Disclosure No. Showa 61-81951, a pallet which is built by combining a top deck with plastic molding supports as given in the Utility Model Disclosure No. Showa 60-78726, a pallet whose supports are made of metal as given in the Patent Disclosure No. Showa 51-93036, and others.

In recent years, a problem of waste disposal has been presented, and in Germany, there has arisen the necessity of an obligation to recover the packaging materials being imposed on the product manufacturers.

The pallet manufacturers must have secured loading and storing places at the lowest possible cost in supplying pallets to the users.

Therefore, to facilitate the waste disposal, corrugated board pallets whose top deck and supports are made of paper, and whose components are all made of the same material have been used.

However, corrugated board pallets given in such documents as the said Patent Disclosure No. Showa 61-81951 presents a problem of strength, such as high sensitivity to moisture, and

1 because they must be carried to the users and stored af ter being assembled at the manufacturers' plants, the expens"es for making transportation and securing the storing space have been great.

The pallets given in the Utility Model Disclosure No. Showa 60-78726 and the Patent Disclosure No. Showa 61-190442 are assembled prior to being used by the user, thus, the cost of transportation is reduced and the storing space requirement is minimized, but because the supports are moldings, the space for storing them is a problem. In addition, the supports are made of plastics and the metallic pallets are of a composite material, a problem of waste disposal is presented.

This invention is provided in consideration of the abovestated situation, and intends to offer a pallet which can easily be disposed as a waste, being highly strong in service, and which can easily be assembled by the user, being manufactured at low cost.

This invention provides a pallet which is built by combining a support 2 consisting of a plate-like support body 25 provided with a support end 23 at the top and a support projection 21 on the said support end 23 with a top deck 10 having a deck hole 22 corresponding to the said support projection 21.

With this composition, a pallet can be offered which can easily be disposed as a waste when discarding it after completion of the use as a pallet, and which, as a pallet itself, is highly strong in service, and can easily be assembled by the user and manufactured at low cost.

In the accompanying drawings:- Fig. 1 is a bird's eye view of the completed assembly of this invention.

Fig. 2 is a bird's eye view of one embodiment of the support 2 of this invention.

F ig. 3 is a bird's eye view of another embodiment of the support of this invention.

Fig. 4 is a bird's eye view of another embodiment of the support of this invention.

Fig. 5 is a partially cut-away bird's eye view which shows the assembly of the pallet which is an embodiment of this invention.

Fig. 6 is a partially cut-away bird's eye view which shows the deck hole 22 in the top deck of another embodiment of this invention.

Fig. 7 is a partially cut-away bird's eye view which shows the deck hole 22 in the top deck of another embodiment of this invention.

Fig. 8 is a partially cut-away bird's eye view which shows the deck hole 22 in the top deck of another embodiment of this invention.

Fig. 9 is a partially cut-away bird's eye view which shows the deck hole 22 in the top deck of another embodiment of this invention.

Fig. 10 is a bird's eye view of another embodiment of the support of this invention.

Fig. 11 is a bird's eye view of another embodiment of the support of this invention.

Fig. 12 is a bird's eye view of another embodiment of the top deck of this invention.

Fig. 13 is a partially cut-away bird's eye view which shows the assembly of the pallet which is another embodiment of this invention.

Fig. 14 is a conceptual bird's eye view for manufacturing of the supports of another embodiment of this invention.

Fig. 15 is a bird's eye view of another embodiment of the assembly of the pallet of this invention.

Fig. 16 is a partially cut-away bird's eye view of another embodiment of the supports of this invention.

3 Fig. 17 is a conceptual bird's eye view for manufacturing of the supports of another embodiment of this invention.

Fig. 18 is a bird's eye view of another embodiment of the assembly of the pallet of this invention.

Fig. 19 is a partially cut-away bird's eye view of another embodiment with the top deck 106 of this invention being removed.

Fig. 20 is a conceptual bird's eye view for manufacturing of the supports of another embodiment of this invention.

Fig. 21 is a bird's eye view of the completed assembly of another embodiment of this invention.

Fig. 22 is a bird's eye view showing the assembly of the parts of this invention.

Fig. 23 is a bird's eye view showing the assembly of another embodiment of this invention.

Fig. 24 is a partially cut-away bird's eye view showing the assembly of another embodiment of this invention.

Fig. 25 is a bird's eye view of the jig for completing the assembly of this invention.

Fig. 26 is a bird's eye view showing the assembly of the supports of another embodiment of this invention.

Fig. 27 is a bird's eye view of the support member of another embodiment of this invention.

Fig. 28 is a development plan of the support members in Fig. 27.

Fig. 29 is a plan of the completed assembly of the support members in Fig. 27.

Fig. 30 is a developmental bird's eye view of the support members of another embodiment of this invention.

Fig. 31 is a bird's eye view of the completed assembly of the support members in Fig. 30.

Fig. 32 is a partially cut-away bird's eye view which shows the deck hole 22 in the top deck of another embodiment of this invention.

4 The pallet of this invention features that it consists of a plate-like top deck, a platelike bottom deck, and plate-like supports carrying the said top deck and bottom deck with a fixed spacing; the said supports are provided with support ends at the upper and lower ends to carry the said top deck and bottom deck and projections on the said support ends; and the top deck and bottom deck are each provided with deck holes corresponding to the said projections.

The function of each invention configured as stated above will be described here.

With the pallet as stated in the claim 1, (A) all the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) if it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the user when required, and the support of this invention is plate -like, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved (D) if it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling.

With the pallet as stated in the claims 2 to 5, (A) all the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily (B) if it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the user when required, and the support of this invention is plate -like, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) if it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling; (E) the amount of materials required is minimum (F) if the deck holes in the top deck were rectangular, creating them would take much time and expense, however, as shown in Fig. 12, the deck holes of this invention are small round holes, which can be easily produced. If the deck holes are square, they can be easily provided; (G) the deck holes are given in the top deck, therefore, in assembling, especially when a deck hole in the central area is misaligned with the support projection, they can be aligned by picking the support projection from above the deck hole with such a tool as an ice pick.

With the pallet as stated in the claims 6 to 9, (A) all the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) if it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the 6 user when required, and the support of this invention is platelike, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) if it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling; (E) because the support body is made integral with the top deck by use of adhesive, the pallet is highly resistant to pressure, and even shock from the side.

With the pallet as stated in the claims 10 to 12, (A) all the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) if it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the user when required, and the support of this invention is plate -like, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) if it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling; Here is a description of the preferred embodiments of this

7 invention by referring to the drawings attached.

Figs. 1 to 9 show the preferred embodiments related to the invention as stated in the claim 1.

Fig. 1 is a bird's eye view of the pallet 1 related to the preferred embodiment of this invention.

The top deck 10 has a flat, rectangular plate-like geometry, and is provided with more than one deck holes 22 in appropriate places that are fitted to the projections 21 of the later-described supports 2. The bottom deck 11 used may be of the same configuration as the said top deck 10.

Fig. 2 is a bird's eye view of the support 2 used with the pallet 1 related to the preferred embodiment of this invention.

This support 2 consists of a support body 25 whose side wall 25a is rectangular plate-like; a support end 23 provided on the upper and lower ends of the support body 25; and a projection 21 provided in the central area of the said support end 23 with a height equal to the thickness of the said top deck 10 being given. By using this support 2, the said top deck 10 and bottom deck 11 can be firmly supported, because the projection 21 is jointed to the deck hole 22 which is provided in the said top deck 10 and bottom deck 11.

Figs. 3 and 4 are bird's eye views of the version preferred embodiments of the support 2 of the said preferred embodiment.

The support 2A as shown in Fig. 3 consists of a support body 25 whose side wall is rectangular plate-like; a support end 23 provided on the upper and lower ends of the support body 25; and a projection 21 provided so that one side wall 25b of the said support body 25 is vertically extended by a height equal to the thickness of the said top deck 10. The support 2B as shown in Fig. 4 is the support 2 as shown in Fig. 2 whose projection 21 is cut off in the portions close to the sides of the support body 25. In other words, the projection 21 is provided so that it is located inside of -the edges of the support end 23.

8 By using these supports 2A and 2B, the said top deck 10 and bottom deck 11 can be firmly supported, because the support end 23 and projection 21 are jointed to the deck hole 22 which is provided in the said top deck 10 and bottom deck 11.

Here, by referring to Fig. 5, how to assemble the support 2 of the pallet 1 to the top deck 10 and bottom deck 11 will be described.

To assemble the pallet 1 related to this invention, the top deck 10 is placed on the ground, work bench, or other appropriate rest, and the projection 21 of the support 2 is inserted into each deck hole 22 in the top deck 10 for jointing. After fitting the support 2 to all the deck holes 22, the deck hole 22 in the bottom deck 11 is fitted to the projection 21 of each support 2 on the side not jointed to the top deck 10 for completion of the pallet 1 of this invention.

Thus, the top deck 10, bottom deck 11, and support 2 are firmly combined with rigidity.

Simply by inserting the projection 21 into the deck hole 22, a rugged pallet can be obtained, however, for higher rigidity, the projection 21 or support end 23 can be coated with adhesive in assembling.

The geometry of the bottom deck 11 used is the same as that of the top deck, however, it is not limited to that.

Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the pallet of the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58-130931.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 10. By doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

9 Figs. 6 to 9 are bird's eye views of the version preferred embodiments of the deck hole 22 of the said preferred embodiment.

The top decks 101 and 102 as shown in Figs. 6 and 7 are provided with deck holes 221 and 222 which are L- and T-shaped, respectively. The length and width of one side of these deck holes 221 and 222 are equal to the length and width of the projection 21 formed on each of the said supports. Into the deck hole 221, two supports are inserted in an Lshape, while into the deck hole 222, two supports are inserted in a T-shape.

Thus, by L or T-shaping the deck hole formed in the deck, the support can also be L- or T-shaped, resulting in that a higher sturdiness can be provided.

The pallet top decks 103 and 104 as shown in Figs. 8 and 9 are provided with deck holes 223 and 224 which have a shape of a triangle, square, or some other polygon.

The length of one side of these polygonal deck holes 223 and 224 is equal to the length of the projection 21 formed on each of the said supports. Thus, by producing the deck hole in the deck in a polygon, a hollow support can be formed, which results in that a sufficient sturdiness can be provided, if the support is made of a material as thin as 3 mm, for example.

The geometry of the bottom deck used, which is not shown, is the same as that of each top deck, however, it is not limited to that.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck. By doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Figs. 10 to 14 show the preferred embodiments related to the inventions as stated in the claims 2 and 4.

The support 2C as shown in Fig. 10 is provided with a support body 25 whose side wall 25a is rectangular plate-like and which has a support end 23 at the upper and lower ends; and a plate-like projection 21 which is bonded to the side wall 25a of the said support body 25 by using adhesive 26 and whose upper and lower ends are protruded from the support body 25.

The support 2D as shown in Fig. 11 is provided with two support bodies 25 whose side wall 25a is rectangular plate-like and which have a support end 23 at the upper and lower ends; and a plate-like projection 21 which is located on the side wall 25a between the said support bodies 25 so that the upper and lower ends are protruded from the support body.

Fig. 12 shows a top deck 10C for use with this preferred embodiment, and the surface of it is provided with deck holes 22 whose size corresponds to the said projection 21.

A rectangular hole takes much time and expense to be produced, while the deck hole 22 in the top deck 10C that corresponds to the support of this preferred embodiment is a small round or square hole, which can be easily produced by means of a drilling machine or a steel rule die, resulting in that the time and expense can be reduced.

By using the support 2C or 2D. the support end 23 and projection 21 are jointed to the deck holes 22 in the said top deck 10C and bottom deck 11C, thus, the said top deck 10C and bottom deck 11C can be firmly supported.

T5e support projection 21 used may be that formed by bonding it to the side wall 25a of the support body 25 with the use of adhesive. The support projection 21 is not always required to be located in the central area of the support body, and it may be in a location displaced from the central area as shown 11 in Fig. 10.

With this preferred embodiment, the geometry of the bottom deck 11C used is the same as that of the top deck 10C, however, it is not limited to that.

Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58-130931.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 10C. By doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Fig. 13 shows the support of this preferred embodiment that is provided with a reinforcing plate.

By providing a reinforcing plate 31 between two adjacent supports 2C, the pressure resistance is increased. This reinforcing plate 31 is fixed by applying adhesive 32 to the areas contacting with the top deck 10C and bottom deck 11C, and the areas contacting with the supports, such as those close to the side ends 33.

With the preferred embodiment as shown in Fig. 13, the support 2C in Fig. 10C is combined with the reinforcing plate 31, however, when the reinforcing plate 31 is provided for a pallet using the support 2D as shown in Fig. 11, it can be fixed simply by inserting the side end 33 into between the two support bodies 25, and the adhesive 32 can be used to bond the reinforcing plate 31 to the four outer peripheral surfaces of the support.

Unless such a reinforcing plate as 31 is used, a rugged pallet can naturally be provided, however, especially when a heavy article is to be loaded, the reinforcing plate 31 will be useful, allowing a pallet with a higher strength to be created.

12 Here is a detailed description of how to manufacture the support of this invention.

Fig. 14 provides a concept drawing of how to manufacture the support 2C of this invention in quantity.

First, long materials 251 cut in lengths for the support body 25 are arranged side by side with a spacing C being given that is equal to double the length by which the support projection 21 is to be protruded from the support body 25. In making the arrangement, the loss in length caused by cutting with a disc saw must be considered.

Then, adhesive is applied to long materials 211 cut in lengths for the support projection 21, and these are bonded to the said support body materials 251, being arranged at right angles to them, with a spacing D equal to the overall length of the support end 23 given.

Then, after the adhesive being cured, a disc saw is used to cut the materials along the dotted lines A and B. Thus, the support 2C, one piece of which is a block surrounded by the dotted lines A and B. can be simply completed.

To make volume production, the long materials 251 for the support body 25 and the long materials 211 for the support projection 21 are piled up in many layers, being bonded, and a period of time for the adhesive being cured is allowed.

When manufacturing the support 2D of the preferred embodiment as shown in Fig. 11, the support projection materials 211 are sandwiched by the support body materials 251, being bonded, and by doing this, volume production can be made simply as is the case with the said support 2C.

Fig. 15 is a bird's eye view of the version preferred embodiment of the support 2C of the said preferred embodiment.

The pallet as shown in Fig. 15 uses the top deck 10C and bottom deck 11C of the same geometry as the said preferred embodiment, and a support 2E longer than the said support 2C. In other words, a single projection is bonded to the support 2C, while to the said support 2E, three projections are bonded. The said support 2E, having a rectangular plate-like side wall, and a length equal to or approximately equal to the width of the top deck 10C, is provided with a support body 25 having a support end 23 at the upper and lower ends, and more than one plate-like projections 21 located on the side wall 25a of the said support body 25 so that the upper and lower ends are protruded from the support body.

The support projection 21 may be bonded to the side wall 25a of the support body 25 with adhesive. In this case, the support projection 21 must be bonded in the location corresponding to the deck hole 22 in the top deck 10C with adhesive 32.

Assembling of the top deck 10C, support 2E, and bottom deck 11C is made in the same way as with the said preferred embodiment.

The support 2F as shown in Fig. 16, having a rectangular plate-like side wall, and a length equal to or approximately equal to the width of the top deck 10C, is provided with two support bodies 25 each having a support end 23 at the upper and lower ends, and plate-like projections 21 located on the side wall 25a between the said support bodies 25 so that the upper and lower ends are protruded from the support body. In other words, this support 2F is the said support 2E to which another support body 25 is added so that the projections are sandwiched.

By using the support 2E or 2F, the support ends 23 and projection 21 are jointed to the deck holes 22 in the said top deck 10C and bottom deck 11C, thus, the said top deck 10C and bottom deck 11C can be firmly supported.

The support body 25 which is added in this preferred embodiment need not be bonded in manufacturing the support itself, and may be bonded as needed in assembling the support with the top deck 10C.

The geometry of the bottom deck used is the same as that 14 of the top deck 10C, however, it is not limited to that. Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58-130931.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 10C. By- doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Here is a detailed description of how to manufacture the support of this preferred embodiment.

Fig. 17 provides a concept drawing of how to manufacture the support 2E of this invention in quantity.

First, more than one long materials 251 cut in lengths for the support body 25 are arranged side by side with a spacing C being given that is equal to double the length by which the support projection 21 is to be protruded from the support body 25. In making the arrangement, the loss in length caused by cutting with a disc saw must be considered.

Then, adhesive is applied to more than one long materials 211 cut in lengths for the support projection 21, and these are bonded to the said support body materials 251, being arranged at right angles to them, with a spacing D equal to the distance between two adjacent deck holes 22 in the top deck 10C given.

Then, after the adhesive being cured, a disc saw is used to cut the materials along the dotted line A.

To make volume production, the long materials 251 for the support body 25 and the long materials 211 for the support projection 21 are piled up in many layers, being bonded, and a period of time for the adhesive being cured is allowed before cutting; thus, efficient manufacturing can be made.

When manufacturing the support 2F of the preferred embodiment as shown in Fig. 16, the support projection materials 211 are sandwiched between the support body materials 251, being bonded, and by doing this, volume production can be made simply as is the case with the said support 2E.

The geometry of the bottom deck used is the same as that of the top deck 10C, however, it is not limited to that. Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58130931.

In addition' with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 10C. By doing so, aload placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Figs. 18 and 19 show the preferred embodiment related to the invention as stated in the claim 8.

Fig. 18 is a bird's eye view of the pallet 1G related to this preferred embodiment.

The top deck 1OG has a flat, rectangular plate-like geometry, and is provided with more than one deck holes 22 in appropriate places that are fitted to the projections 21 of the later-described supports 2G. The bottom deck 11G used may be of the same configuration as the said top deck 1OG.

Fig. 19 is a bird's eye view of the support 2G used with the pallet 1G related to the preferred embodiment of this invention.

This support 2G, having a rectangular plate-like side wall 25a, and a length equal to or approximately equal to the width of the top deck 1OG, is provided with a support body 25 (with the same geometry as that of the support body of the support 2E as shown in Fig. 15) having a support end 23 at the upper 16 and lower ends, and more than one plate-like projections 21 located on both side walls 25a of the said support body 25 so that the upper and lower ends are protruded from the support body. By using this support 2G, the support end 23 and projections 21 are jointed to the deck holes 22 in the said top deck 1OG and bottom deck 11G, thus, the said top deck 1OG and bottom deck 11G can be firmly supported.

The support projections 21 may be bonded to both side walls 25a of the support body 25 with adhesive. In this case, the support projections 21 must be bonded in the location corresponding to the deck hole 22 in the top deck 1OG with adhesive.

Assembling of the top deck 1OG, support 2G, and bottom deck 11G is made in the same way as with the said preferred embodiment.

If the shape of the deck holes 22 provided in the top deck 1OG and bottom deck 11G is a circle as shown in Fig. 19, they can be produced the most easily, however, the shape is not limited to a circle, and a rectangle surrounding the heads of the two support projections 21 arranged in parallel to each other, as shown in Fig. 18, can be used.

If the lateral length of the support 2G of this preferred embodiment is made equal to that of the support body of the support 2C as shown in Fig. 10, a single pallet can be provided with nine independent supports. In this case, the lift truck fork can be inserted into the pallet in any one of the four directions.

Here is a detailed description of how to manufacture the support of this invention.

Fig. 20 provides a concept drawing of how to manufacture the support 2G of this invention in quantity.

First, more than one long materials 251 cut in lengths for the support body 25 are arranged side by side with a spacing C being given that is equal to double the length by which the support projection 21 is to be protruded from the support 17 body 25. In making the arrangement, the loss in length caused by cutting with a disc saw must be considered.

Then, adhesive is applied to more than one long materials 211 cut in lengths for the support projection 21, and these are bonded to the said support body materials 251, being arranged at right angles to them, with a spacing D equal to the distance between two adjacent deck holes 22 in the top deck 1OG given.

The geometry of the bottom deck used is the same as that of the top deck 1OG, however, it is not limited to that. Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58-130931.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 1OG. By doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Figs. 21 and 22 show the preferred embodiment related to the invention as stated in the claim 10.

Fig. 21 is a bird's eye view of the top deck 10H and bottom deck 11H of the pallet 1H of this invention.

The top deck 10H has a flat, rectangular plate-like geometry, and is provided with more than one deck holes 22 arranged in appropriate places in sets of four that are fitted to the later 18 -described supports 2H. The bottom deck 11H used may be of the same configuration as the said top deck 10H.

Fig. 22 is an explosion bird's eye view of a part of the pallet 1H related to the preferred embodiment of this invention.

This support 2H consists of a combination of two support bodies 25 and 25' having the same geometry, and the said support body 25, having an approximately rectangular plate-like side wall, is provided with support ends 23 at the upper and lower ends for carrying the top deck 10H and bottom deck 11H, and projections 21 protruded at both edges of the said support ends 23, and has a support assembling cutout 24, which is given perpendicularly from the central area of either of the upper and lower support ends 23 towards the center of the support body 25. To form a support, as shown in Fig. 22, two different support bodies, that is to say, the support body 25 whose support assembling cutout 24 is directed downward, and the support body 25' whose support assembling cutout 24' is directed upward, having the same geometry as that of the said support body 25, are used, and the support body 25 located in an upper position and the support body 25' located in a lower position so that it is crossed perpendicularly to the support body 25 are vertically fitted to each other by means of the support assembling cutouts 24 and 24'. The support 2H thus assembled has a cross-shaped section, a cross-shaped support end 23 at the upper and lower ends, and four projections 21 at the edges of each of the said upper and lower support ends 23, providing a high rigidity.

Because the cross-shaped support ends 23 and the four projections 21 are jointed to the deck holes 22 provided in the said top deck 10H and bottom deck 11H, the said top deck 10H and bottom deck 11H can be firmly supported.

With this preferred embodiment, the deck hole 22 has an easy-to-produce shape of a circle, however, the deck hole shape is not limited to a circle, and a square can be used as the shape.

19 The length of the support assembling cutout 24 is equal to or longer than half the height of the support; the shape must not always be rectangular and the cutout opening edges may be chamfered for easier jointing.

To increase the rigidity and integrity of the pallet, the projections 21 or support ends 23 can be coated with adhesive in assembling. After completion of the assembling, the adhesive can be applied from the top deck hole 22.

With this preferred embodiment, four deck holes 22 are provided in the top deck 10H for the four support projections 21, however, if the support has a high strength, the number of deck holes 22 can be reduced f rom f our to two.

The geometry of the bottom deck used is the same as that of the top deck 10H, however, it is not limited to that. Even with this preferred embodiment, the bottom deck itself can be eliminated as is the case with the Utility Model No. Showa 49-32074, or the bottom deck can comprise three small plates rather than a single plate as is the case with the Utility Model No. Showa 58-130931.

In addition, with this preferred embodiment, the projection 21 can be made to protrude above the flat surface of the top deck 10H. By doing so, a load placed on the top deck can be prevented from being laterally slided, and the protruded portion of the support projection 21 can conveniently be hammered in disassembling.

Fig. 23 shows another preferred embodiment related to the invention as stated in the claim 15, providing an explosion bird' s eye view of a part of the pallet M of this preferred embodiment.

The top deck 10J has a flat, rectangular plate-like geometry, and is provided with more than one deck holes 22 arranged in appropriate places that are fitted to the later-described supports 2J. The bottom deck 11J used may be of the same configuration as the said top deck 10J.

This support 2J consists of a combination of two support bodies 25 and 25' having the same geometry, and the said support body 25, having an approximately rectangular plate-like side wall, is provided with support ends 23 at the upper and lower ends for carrying the top deck 10J and bottom deck 11J, and a projection 21 protruded in the central area of the said support ends 23, and has a support assembling cutout 24, which is given perpendicularly from the central area of either of the upper and lower support ends 23 towards the center of the support body 25. The support body 25' has the same geometry as that of the support body 25. To form a support with these support bodies 25 and 2T, as shown in Fig. 23, two support bodies, that is to say, the support body 25 whose support assembling cutout 24 is directed downward, and the support body 25' whose support assembling cutout 24' is directed upward, are used, and the support body 25 located in an upper position and the support body 25' located in a lower position so that it is crossed perpendicularly to the support body 25 are vertically fitted to each other by means of the support assembling cutouts 24 and 24'. The support 2J thus assembled has a cross-shaped section, a cross-shaped support end 23 at the upper and lower ends, and a cross-shaped projection 21 in the central area of each of the said support ends 23, providing a high rigidity.

By using this support 2J, the cross-shaped support ends 23 and the projections 21 are jointed to the deck holes 22 provided in the said top deck 10J and bottom deck 11J, thus, the said top deck 10J and bottom deck 11J can be firmly supported.

When compared to the pallet related to the preferred embodiment as shown in Fig. 21, the pallet of this preferred embodiment is simple in manufacture and assembly, because a single deck hole is required to be produced for one support.

With this preferred embodiment, the deck hole 22 has an easy-to-produce shape of a circle, however, the deck hole shape is not limited to a circle, and a square deck hole or a crossshaped deck hole can be used.

21 Figs. 24 and 25 show a mechanism to prevent the support 2J from being disconnected from the deck after completion of assembling the pallet of the preferred embodiment as shown in Fig. 23.

Fig. 24 is a plan of the deck hole 22 in the top deck 10K, and the shape of this deck hole 22 is not an exact circle; convex portions 26 which reduce the opening diameter of the 'deck hole 22 that is slightly larger than the length of the projection 21 of the support 2J are provided on the circumference of the deck hole 22.

The tool 28 as shown in Fig. 25 is used to turn the support 2J assembled in a cross shape; to do so, the cutout 31 is fitted to it from above, and the handle 41 is turned in the direction of arrow.

With the turn of the tool 28, the support 2J is turned, resulting in the end of the support projection 21 being applied to the convex portion 26 of the deck hole 22 with a strong force, thus, disconnection of the support can be prevented. Disassembling can be made simply by reversing this procedure.

Figs. 26 to 32 show the preferred embodiments for making the shape of the support to be a polygonal prism, such as a triangular one.

Fig. 26 shows the preferred embodiment with which two support assembling cutouts are provided for a single support body.

The three support bodies 25 and 25' as shown in Fig. 26 form a set, and by engaging two adjacent support assembling cutouts with each other for any couple of support bodies, the sides of a triangular prism-like support 2L are formed. Each projection 21 of the assembled support 2L provides a side of an approximately regular triangle, and the projections are inserted into the triangular deck hole 22 in the top deck 10L and bottom deck 11L.

This support 2L consists of a combination of two different 22 types of support bodies 25 and 25' having similar geometries, and the said support body 25, having an approximately rectangular plate-like side wall, is provided with support ends 23 at the upper and lower ends for carrying the top deck 10L and bottom deck 11L, and a projection 21 protruded in the central area of the said support ends 23, and has two support assembling cutouts 24 (providing an W- or N-shaped plane figure), which are given perpendicularly to the support end 23 from the areas close to the right and left ends of either of the upper and lower support ends 23. The support body 25' is provided with two support assembling cutouts 24', which are arranged so that they are symmetrical with respect to a point, i.e., an approximately N-shaped plane figure is provided.

To form a support with these support bodies 25 and 25', as shown in Fig. 26, three support bodies, that is to say, the support body 25 whose support assembling cutout 24 is directed downward, the support body 25 whose support assembling cutout 24 is directed upward, and the support body 25' are used, and the support assembling cutout 24 in the support body 25 located in a lower position is engaged with the support assembling cutout 24' in the support body 25' located in an upper position so that it is crossed to the support body 25 at an angle of approx. 60 deg., then, the support assembling cutouts 24 of the remaining support body 25 are engaged with the support assembling cutouts 24 and 24' in the previously connected support bodies 25 and 25' to form a support 2L. The support 2L thus assembled has an approximately triangular section, providing a rugged support.

In Fig. 26, three support members are used to form a triangular prismlike support, however, an appropriate number of these two different types of support bodies can be combined to form a polygonal prism-like support, such as a quadrangular prismlike one.

Thus, when the support body is provided with two assembling 23 cutouts, the geometry of the support is not limited to the said preferred embodiment, and a support of any geometry (a star shape, for instance) can be created by combining more than one support bodies and matching the geometry of the support with that of the deck hole 22 in the top deck.

Figs. 27 to 29 show the preferred embodiment with which a support allowing the material to be utilized efficiently can be provided.

Fig. 27 is a bird's eye view of the support body 25 constituting the support 2M related to this preferred embodiment.

This support body 25 has a vertically long, plate-like side wall, and on both sides of the said support body, the engaging convex portion 29 and the support assembling cutout 24 are arranged one above the other so that, when supports are connected horizontally as shown in Fig. 28, they are tightly engaged with one another, while at the upper and lower ends, the support ends 23 for carrying the top deck and bottom deck (not shown) are provided with the projection 21 being protruded in the central area of the said support end 23.

Fig. 29 shows a top view of the support 2M assembled by using three support bodies 25.

In Fig. 29, three support members are used to form a triangular prismlike support, however, an appropriate number of support bodies can be combined to form any geometry of support including a polygonal prism-like support, such as a quadrangular prismlike one.

Figs 30 and 31 show the support related to another preferred embodiment.

The first panel 33, second panel 34, and third panel 35, which are platelike, having the same size, and the fourth panel 36, the upper and lower ends of which are recessed from those of the panels 33 to 35, respectively, to form the support ends 23 for carrying the top deck and bottom deck (not shown), are connected side by side by applying the back liner 40 to 24 the back of each panel.

When the support 2N is folded at the folding lines 37 with the surface backed up by the back liner 40 being made inside, it is provided with a triangular prism-like shape as shown in Fig. 31. This causes the fourth panel 36 to be wrapped around the periphery of the triangular prism formed by the first panel 33, second panel 34, and third panel 35. The support 2N thus assembled has projections 21 at the upper and lower ends of the first to third panels, and support ends 23 at the upper and lower ends of the fourth panel.

The fixing member 39 in the fourth panel 36 and the fixing hole 38 in the first panel 33, which corresponds to the fixing member in the fourth panel 36, are made integral by inserting the fixing member 39 into the fixing hole 38, preventing disconnection and thus permitting the said support 2N to be reliably secured. The fixing hole 38 and the fixing member 39 must not always be located in the first panel 33 and the fourth panel 36, respectively.

If adhesive is used to joint the first panel 33 to the fourth panel 36, the support 2N can be formed with no need for using the fixing hole 38 and the fixing member 39.

With this preferred embodiment, only the fourth panel provides the support ends 23, however, more than one panels can be provided to increase the strength.

In addition, with this preferred embodiment, the fourth panel is caused to wrap round the first panel 33, however, the upper and lower ends of a single plate can be shouldered by use of an automatic planer to provide the support ends 23 and the support projections 21 in an integrated part of the first panel 33 and the fourth panel 36.

In Figs. 30 and 31, a triangular prism-like support is formed, however, an appropriate number of panels can be combined to form any geometry of support including a polygonal prismlike support, such as a quadrangular prismlike one.

Fig. 32 shows a partially enlarged view of the panel deck in which a triangular deck hole 22 adapted to the supports as shown in Figs. 26 to 31 is formed. The said deck hole 22 is produced in an appropriate polygon, such as a square, to adapt to the geometry of the said support. For any polygonal prism, the deck hole 22 can be shaped circular to allow the support projections to be fitted into it.

As the material for the pallet of each preferred embodiment of this invention, which is described above in detail, it is desirable to use particle boards or plywood laminates. Using the same material or similar materials for the three different parts of the top deck, bottom deck, and support simplifies the recovery after use, and is desirable for waste disposal.

The materials used must be as thin as 3 mm to as thick as 9 mm, however, the support must not always have the same thickness as the top deck, and may be made of a material having the proper thickness for the weight of the load or other factor.

Here is a detailed description of how to produce the parts of the pallet related to this preferred embodiment.

The three different parts of the top deck, bottom deck, and support are produced by blanking the material into the geometry with the use of a combination of a steel rule die and a hydraulic press. A carbon dioxide laser cutter can also be used f or manufacturing. If the material used is as thin as 3 mm, an automatic blanking machine for fabrication of paperboard cartons can be used for high speed production.

The projection 21 provided for the support can be produced with a tenoning machine or it can be bonded to the support end 23 with adhesive, If the material is as thick as over 9 mm, it cannot be blanked easily, thus, when a thickness of, say, 18 mm is -required, two 9-mm thick plates placed one on another can be easily worked.

If a 9-mm thickness is required, three 3-mm plates can be piled up.

26 This invention is not limited to the above- stated embodiments, and permits various variants to be embodied within the scope of the claims.

This invention described above in detail provides the following effects:

With the invention as stated in the claim 1, it is possible to offer a pallet featuring that:

(A) All the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) If it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the user when required, and the support of this invention is platelike, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) Because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) If it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling.

With the invention as stated in the claims 2 to 5, it is possible to offer a pallet featuring that:

(A) All the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) If it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the 27 user when required, and the support of this invention is platelike, the storing space required is small as compared to the pallet using paper tubes as the supports; (C) Because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) If it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling (E) The amount of materials required is minimum (F) If the deck holes in the top deck were rectangular, creating them would take much time and expense, however, as shown in Fig. 12, the deck holes of this invention are small round holes, which can be easily produced. If the deck holes are square, they can be easily provided; (G) The deck holes are given in the top deck, therefore, in assembling, especially when a deck hole in the central area is misaligned with the support projection, they can be aligned by picking the support projection from above the deck hole with such a tool as an ice pick.

With the invention as stated in the claims 6 to 9, it is possible to offer a pallet featuring that:

(A) All the parts of the pallet are made of the same wooden material or similar wooden materials, thus waste disposal can be performed easily; (B) If it is delivered to the user without being assembled or completed by the pallet manufacturer, the user himself assembles it, resulting in the transportation cost being cut and the storing space being minimized, and because it can be assembled by the user when required, and the support of this invention is platelike. the storing space required is small as compared to the pallet using paper tubes as the supports 28 (C) Because it is of assembly type, it can be disassembled to be stored when not in use, resulting in a minimum space requirement, and by reassembling it, reuse can be achieved; (D) If it is made of particle boards or plywood laminates, providing slipperiness, slightly protruding the support projection 21 from the deck hole 22 will assure slip resistance. In addition, the protruded projection can easily be brought out of place by hammering it in disassembling; (E) Because the support body is made integral with the top deck by use of adhesive, the pallet is highly resistant to pressure, and even shock from the side.

With the invention as stated in the claims 10 to 12, it is possible to offer a pallet featuring that:

29

Claims

1. A pallet formed by combining the support 2 consisting of a platelike support body 25 which is provided with a support end 23 at the upper end and a support projection 21 on the said support end 23, with the top deck 10 which is provided with a deck hole 22 corresponding to the said support projection 21.

2. A pallet formed by combining the support 2C consisting of a plate-like support body 25 which is provided with a support end 23 at the upper end and to the side of which a support projection 21 is bonded, with the top deck 10C which is provided with a deck hole 22 corresponding to the said support projection 21.

3. The pallet as stated in the claim 2 which is formed by bonding a reinforcing plate 31 to the said support 2C or the top deck 10C.

4. A pallet formed by combining a support 2D consisting of two plate-like support bodies which are provided with a support end 23 at the upper end; a support projection 21 fixed between the said two support bodies 25; a reinforcing plate 31 inserted between the said two support bodies 25; and the top deck 10C which is provided with a deck hole 22 corresponding to the said support projection 21.

5. The pallet as stated in the claim 2 for which the said support 2C is obtained by arranging support body materials 251 cut in lengths with a spacing being given that is equal to double the length by which the support projection 21 is to be protruded from the support body 25; by arranging support projection materials 211 cut in lengths at right angles to the said support body materials 251 with an appropriate spacing, and then bonding them; and by cutting the said support body materials 251 approximately in the middle between the said support projection materials 211 and the said support projection materials 211 approximately in the middle between the said support body materials 251.

6. A pallet formed by combining the support 2E consisting of a plate-like support body 25 which is provided with a support end 23 at the upper end; more than one support projections 21 bonded to either side of the said support body 25 of the support 2E; and the top deck 10C which;.s provided with deck holes 22 corresponding to the said support projections 21 of the said support 2E.

7. The pallet as stated in the claim 6 for which the said support 2E is obtained by arranging support body materials 251 cut in lengths with a spacing being given that is equal to double the length by which the support projection 21 is to be protruded from the support body 25; by arranging support projection materials 211 cut in lengths at right angles to the said support body materials 251 with an appropriate spacing, and then bonding them; and by cutting the said support projection materials 211 approximately in the middle between the said support body materials 251.

8. A pallet formed by combining the support 2G consisting of a plate-like support body 25 which is provided with a support end 23 at the upper end; more than one support projections 21 bonded to both sides of the said support body 25 of the support 2G; and the top deck 1OG which is provided with deck holes 22 corresponding to the said support projections 21 of the said support 2G.

9. The pallet as stated in the claim 8 for which the said support 2G is obtained by arranging support body materials 251 cut in lengths with a spacing being given that is equal to double the length by which the support projection 21 is to be protruded from the support body 25; by arranging support projection materials 211 cut in lengths at right angles to the said support body materials 251 with an appropriate spacing, and then bonding them; and by cutting the said support projection materials 211 approximately in the middle between the said 31 support body materials 251.

10. A pallet formed by combining a set of supports 2H consisting of platelike support bodies 25 and 25' which are provided with a vertical support assembling cutout 24 or 24', a support end 23 at the upper end, and support projections 21 at both edges of the said support end 23, and are designed to be assembled vertically, with the top deck 10H which is provided with deck holes 22 corresponding to the said support projections 21 of the said support 2H.

11. A pallet formed by combining a set of supports 2M consisting of platelike support bodies 25 which are provided with horizontal support assembling cutouts 24, a support end 23 at the upper end, and a support projection 21 at the said support end 23, and are designed to be assembled horizontally, with the top deck IOL which is provided with a deck hole 22 corresponding to the said support projections 21 of the said support 2M.

12. A pallet formed by combining a support 2N consisting of a plate-like support body 25 which has a support projection 21 at the upper end and comprises at least three panels 33, 35, and 35, which can be rolled up into a prism at vertical folding lines 37; a panel 36 which has a support end 23 at the upper end and is provided so that it is wrapped round the periphery of the prism formed by rolling up the said panels of the said support 2N, with the said support end 23 positioned slightly under the said support projection 21; and the top deck 10L which is provided with a deck hole 22 corresponding to the said support projections 21.

32