GB2414724A

GB2414724A - A flexible mat for use under pallets to aid in loading and unloading

Info

Publication number: GB2414724A
Application number: GB0412347A
Authority: GB
Inventors: Gary Philip Speller
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-06-03
Filing date: 2004-06-03
Publication date: 2005-12-07
Anticipated expiration: 2024-06-03
Also published as: GB2414724B; GB0412347D0

Abstract

A flexible mat 1 has means to engage 3 a load as it is pushed into a space, so that the load slides into the space with the mat 1, and means for pulling 5D the mat 1 with its load back for unloading. The means to engage 3 the load may be a projection from an upper surface of the mat 1 close to one edge, the projection may be a flexible strip. The mat 1 may have flexible runners 4 attached to the lower face of the mat 1. The means for pulling may include flexible strips 4, each being attached along the mat in a direction from front to back and forming a loop 4A which extends from a rear edge of the mat 1. A method of transporting or storing loaded pallets by means of placing a load on a flexible mat, pushing the pallet so it slides on the mat into a space, and after transportation or storage, pulling the mat with its load to an access point is also disclosed.

Description

24 1 4724

LOADING MAT

This invention relates to a mat for facilitating the loading and unloading of pallets into and out of spaces having restricted access.

When loaded pallets are transported by road in medium-size vans, it is usual to use a fork-lift truck to lift the pallet into the van and then to push the pallet towards the front, making space for a second pellet behind it. If there is room for more than two pallets, the process can be repeated, this time both pallets being pushed simultaneously forward to create a space for a third pallet. This loading process is relatively problem free.

The terms "rearward" and "back" are used in this specification to refer to positions close to an access point (eg the back of a van); and the terms "forward" and "front" are used conversely to refer to positions remote from the access point (eg the front of a van).

Unloading the pallets is more difficult than loading. After the first pallet has been removed, it is necessary to attach a tie to the next pallet so that it can be pulled to an unloading point before the forklift is used in the normal way for unloading. Unfortunately, conventional wooden pallets are insufficiently strong to survive treatment like this without risk of damage. Sometimes the very high tension in the rope causes the part of the pallet to which it is attached to break - 2 off, often with nails attached, and to be catapulted with potentially lethal velocity, towards the fork-lift driver. Until now, there has been no practicable way of avoiding this serious safety hazard.

This invention provides a flexible mat designed to assist in carrying a load in and out of a confined space, the mat having means to engage the load as it is pushed into the space so that the mat slides into the space with the load, and means for pulling the mat with its load back for unloading.

According to another aspect of the invention there is provided a method of transporting or storing loaded pallets in a space having a restricted access point, comprising: placing a flexible mat in the space adjacent to the access point; placing a loaded pallet on the mat using a fork-lift truck; pushing the loaded pallet with the truck so that it slides on the mat into a desired position in the aforementioned space; and, after transportation or storage, pulling the mat with its load back to a position adjacent the access point.

The confined space referred to above will normally be the interior of a van but the invention could also be useful when loading pallets onto other surfaces. For example, if a truck were parked so that it could be accessed from only one side, the invention would facilitate loading and unloading from that side. - 3

The aforementioned "means to engage the load" ensures that the mat does not slip from under the load as the load is pushed back into the space during loading; or as the mat is pulled back during unloading. Any form of projection or projections from the upper surface of the mat can be used to provide this function, preferably without compromising the overall flexibility of the mat. A single strip of flexible webbing stitched along the front edge of the mat has been found to be very effective.

The facility for pulling the mat can take any one of a variety of different forms.

A preferred arrangement uses lengths of webbing folded double to form loops close to the rear corners of the mat, the webbing being stitched, or otherwise attached to the mat. If this webbing is stitched to an underside of the mat and made to extend substantially along its whole length, it forms runners, helping the mat to slide over the surface on which it rests. In alternative constructions it may be possible to assist this sliding action in other ways, for example by using a mat which has a smooth material attached to its lower surface.

The pulling of the mat is preferably facilitated by a relatively rigid bar attached to a rear edge of the mat and provided with a suitable attachment point for connection to the fork-lift. The bar can be connected to the mat by loops of webbing as previously described. The use of this bar allows the pulling force to be applied directly rearward at the different points of attachment to the mat so as to avoid any tendency for the corners to be pulled together. It has been found that this bar can also be of assistance during the loading process because it can be positioned along the edge of the pallet and used by the fork-lift to push the pallet forward, distributing the force evenly across the width of the pallet.

One way of performing the invention will now be described by way of example with reference to the accompanying drawings in which: Fig 1 is a perspective view, shown schematically and not to scale, of a loading mat constructed in accordance with the invention, illustrating also a wooden pallet which the mat is designed to carry; and Fig 2 illustrates the process by which the mats like that shown in Fig 1 are used to load pallets into a van.

Referring firstly to Fig 1 there is illustrated a flexible sheet 1 of woven synthetic plastics material which, in this particular example is a mixture of polypropylene and nylon. The width (w) is approximately 1000mm and the length (1) is approximately 1300mm; so that the sheet is comfortably able to receive a standard pallet 2 having a width of 800mm and a length of 1 000mm.

Stitched to an upper surface of the sheet 1 is a strip 3 formed from three or four layers of polyester webbing about 50mm wide. These lengths of webbing are attached two lines of stitching along respective edges. The strip 3 projects from the upper surface of the sheet 1 so as to catch against the front edge 2A of the pallet in a way which will be described later.

Stitched to the bottom surface of the sheet 1, close to its side edges, are two 75mm wide strips of polyester webbing 4. Each of these strips is folded double so as to form a loop 4A. Because these strips are attached along the whole length of the mat they are able to provide an exceptionally strong attachment whereby the mat and its load can be pulled across a surface on which it rests.

The double-thickness of the folded strips also provides the effect of runners to facilitate sliding movement. If desired, one or more extra thicknesses of webbing can be added to increase the depth of these runners.

Attached to the rear edge of the sheet 1 is a bar 5 which in this particular embodiment is moulded from a mineral-filled, nylon-reinforced, synthetic plastics, though in alternative constructions it could be made of steel plate. This bar is formed with two outer slots 5A through which respective loops 4A pass.

It is also formed with slots SB for attachment to a flexible strap, allowing the mat to be pulled backward in a manner to be described later. The principal purpose of the bar 5 is to ensure that both side edges of the mat are pulled, by the webbing 4, directly rearward. Trials conducted, without the bar, resulted in the loops 4A being pulled towards each other, this hindering the smooth sliding action of the mat over the surface on which it rested. - 6

Loops SD of webbing also pass through the slots SA and are used to help when lifting, or adjusting the position of, the bar S. In this particular embodiment, the loops SD are separate pieces of webbing stitched to form a loop but in an alternative construction they could be continuations of the loops 4A. s

Fig 2 shows the process of loading and unloading a van 6 from its rear access point 7 for the transport of materials as part of a manufacturing process. First, a mat like that shown in Fig 1 is placed on the floor of the van close to the access point and a fork-lift 8 is used to load a pallet 2, carrying goods 9, onto the mat.

The bar S is positioned by hand, using the loops SD as handles, so that it lies along the rear edge 2C (Fig 1) of the pallet; and the fork-lift 8 is then used to push the pallet forward, towards the front of the van. Initially the pallet may slide on the mat until a front edge 2A engages the projecting strip 3 (Figl). The mat with its load then slides easily to a position mid-way between the positions 1 S 6A and 6B of Fig 2.

A second mat, similar to the first, is now placed on the van floor near the access point and the next load 9 is placed on it. This is then pushed forward in the same way as previously described until the two loads assume the positions 6A and 6B.

During the unloading procedure, the first load, at position 6A, can easily be removed using the fork-lift in the normal way. The load at position 6B cannot - 7 however be reached by the prongs of the fork-lift. Conventionally therefore, one end of a rope or strap would be attached to the fork-lift and the other end attached to one of the central spacers 2B of the pallet 2. The pallet and its load would then be pulled to the position 6A. It is this process which previously presented a serious safety hazard because the spacer 2B sometimes broke away from the rest of the pallet and was projected towards the driver of the fork-lift.

This risk is now avoided because the attachment is made, not directly to the pallet, but instead to a central point on the bar 5. This allows the load to be easily and smoothly moved to position 6A, adjacent the access point 7, from where it can be unloaded in conventional manner. As the load is pulled to the position 6A the engagement of strip 3 with the front edge of the pallet prevents the mat from being pulled from underneath the pallet. A strap 10, shown on Fig 1, with a hook 10A at each end is provided for use during the unloading process. One end of this strap is wrapped around a post 8A (Fig 2) of the fork lift and hooked onto itself; whilst the other end is hooked directly onto the central slot 5B of the bar 5. Alternatively, both hooks 10A could be attached to the slots 5C with the webbing passing around the fork-lift post.

Trials have shown that the illustrated mat greatly facilitates loading and unloading and it is believed that the invention will prevent future serious injuries. Furthermore, the illustrated mat is remarkably convenient to store and carry, its flexible nature allowing it to be folded or rolled up and stored for example in a corner of the van when not in use. - 8

Claims

1. A flexible mat designed to assist in carrying a load in and out of a confined space, the mat having means to engage the load as it is pushed into the space so that the mat slides into the space with the load, and means for pulling the mat with its load back for unloading.

2. A mat according to Claim 1 in which the means to engage the load is a projection from an upper surface of the mat close to one edge thereof.

3. A mat according to Claim 2 in which the projection is a flexible strip extending along one edge of the mat.

4. A mat according to any preceding Claim in which the means for pulling the mat comprises a relatively rigid bar connected at points spaced along an edge of the mat.

5. A mat according to any preceding Claim in which the lower face of the mat is designed or adapted to facilitate sliding of the mat.

6. A mat according to Claim 5 comprising flexible runners attached to the lower face of the mat.

7. A mat according to any preceding Claim in which the means for pulling includes flexible strips, each being attached along the mat in a direction from front to back and forming a loop which extends from a rear edge of the mat.

8. A mat according to Claim 7 when dependent on Claim 6 in which the strips define the said runners.

9. A mat according to Claim 7 or 8 when dependent on Claim 4 in which the loops are attached to the bar.

10. A mat according to any preceding Claim made of woven synthetic plastics material.

11. A method of transporting or storing loaded pallets in a space having a restricted access point, comprising: placing a flexible mat in the space adjacent to the access point; placing a loaded pallet on the mat using a fork-lift truck; pushing the loaded pallet with the truck so that it slides on the mat into a desired position in the aforementioned space; and, after transportation or storage, pulling the mat with its load back to a position adjacent the access point.

12. A method according to Claim 11 in which a rigid bar, attached along a rear edge of the mat, is used to pull the mat. -

13 A method according to Claim 12 in which the bar is also used to push the pallet.