GB2465964A

GB2465964A - Deck for transporting a shrinkwrapped load

Info

Publication number: GB2465964A
Application number: GB0818598A
Authority: GB
Inventors: Ian Charles West; Stephen Donald Sole
Original assignee: LOGIDECK Ltd
Current assignee: LOGIDECK Ltd
Priority date: 2008-10-10
Filing date: 2008-10-10
Publication date: 2010-06-09
Also published as: GB0818598D0

Abstract

A deck for transporting a load comprises a generally planar sheet having a circumferential edge with at least one elongate recess extending along at least part thereof. The recess may be manufactured by cutting using a suitable tool or formed during moulding of the deck. The recess provides a location for a shrinkwrap covering to grip the deck and be retained in place. At least one edge may have a portion to which no recess extends, said portion including a visible indicia such as a barcode. The recess may have a variety of cross-sections, such as arcuate or stepped, and may be substantially hollow, for ease of manufacture and to reduce its weight. The deck may comprise upper and lower skins sandwiched together with a hollow interior such as a honeycomb pattern, such interior allowing a remotely readable identifier such as an RFID tag to be retained.

Description

Deck for transporting a load

FIELD OF THE INVENTION

The present invention relates to a deck for transporting a load.

BACKGROUND ART

The wooden pallet has been the standard means of transporting goods since its invention about 60 years ago. Although a vast improvement on prior arrangements for freight transport, the pallet is highly unsatisfactory.

Fabricated from wood, a pallet is a bulky and heavy item which must be transported along with the goods themselves. It is also prone to absorb water and contaminants when placed in a damp environment, which weaken the pallet, increasing its weight, and distribute those contaminants to other locations and to subsequent loads. The increase in weight can be significant; a dry pallet typically weighs 26kg but this can rise to 40kg when wet. As a typical load involves some 20+ pallets, this increase corresponds to a total increase of at least 280kg, which may cause a vehicle loaded in the dry but then exposed to wet weather to exceed its maximum loading.

As a natural material, a pallet is also vulnerable to various forms of decomposition and must therefore be treated with pesticides and/or antifungal agents. As the pallet ages, it produces splinters and loose nails, presenting a health & safety hazard. It might be thought that a natural material would be susceptible to recycling, but the paint and pesticides applied to a pallet generally mean that the only safe disposal option is to burn it, thereby releasing the stored Carbon as CO2. Given that a wooden pallet has a typical life of 8 journeys, this is a considerable wastage of wood.

Previous efforts to replace the wooden pallet include US 4,972,782, which provides p!ast!cs pIIet supoort which can, if desired, travel with the load thereby negating the advantages to be obtained. Alternatively, the support can be left in situ and the load supported on a flat wooden deck. This has the advantage of reducing the weight and height of the complete load, but retains all the disadvantages surrounding the use of wood. Further, it is not clear how a shrinkwrap coating of the type that is commonly used to fix the load safely to the pallet could be applied to a deck of this design.

WO 2005/090176 proposes a flat deck that can be supported on loose composite box-section struts. This is likely to be difficult in practice, as the struts are n-iovable. Again, it is unclear how a shrinkwrap coating could be applied.

SUMMARY OF THE INVENTION

The present invention therefore provides a deck for transporting a load, comprising a generally planar sheet having a circumferential edge, the edge having at least one elongate recess extending along at least part thereof. Such a deck is straightforward to manufacture -the recess can be cut by a suitable tool or it can be formed during moulding of the deck. The recess does however provide a location on the deck for a shrinkwrap covering to "grip" the deck and thus be retained in place.

The recess can extend along (only) a part of the edge, if desired. Where the deck consists of a sheet having a shape that includes corners, it is preferable for the recess to extend along the edge from a corner of the sheet towards a mid-point. This ensures that the recess is present at a corner where it is most easily engaged by shrinkwrap.

Generally, the sheet will be a shape including several corners, such as a square or rectangle. In this case, there are preferably a plurality of recesses, one extending from each corner.

It is also useful if there is at least one edge which include a portion to which no recess extends. That portion can then include a visible indicia which will be easily readable. The visible indicia can be a barcode, for example, or another form of mc.hine-readable indicia.

The recess can have an arcuate cross-section, such as a semi-circular shape. Alternatively, it can be stepped. Different cross-sections will generally lend themselves to different manufacturing methods.

The deck can be substantially hollow, for ease of manufacture and to reduce its weight. It can, for example, comprise upper and lower sections sandwiched together to define the deck. The interior can be hollow or substantially hollow, such as a honeycomb pattern. A further advantage of an at least partly hollow interior is that this allows for a remotely readable identifier such as an RFID tag to be retained safely.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described by way of example, with reference to the accompanying figures in which; Figure 1 is a perspective view of a deck according to the present invention; Figure 2 is a perspective view of an internal spacer for a deck according to the present invention; Figure 3 is a partial view along an edge of a deck according to the present invention; Figure 4 is a perspective view of the middle portion of the edge depicted in figure 3; -4..

Figure 5 is a partial view along an edge of a deck according to an alternative embodiment of the present invention; Figure 6 is a perspective view of the middle portion of the edge depicted in figure 5; Figures 7, 8 and 9 show side, end and top views of a first embodiment of a deck rail for supporting a deck according to the present invention; Figures 10, 11 and 12 show side, end and top views of a second embodiment of a deck rail for supporting a deck according to the present invention; Figures 13, 14 and 15 show side, end and top views of a first embodiment of a support platform for supporting a deck according to the present invention; Figures 16, 17 and 18 show side, end and top views of a second embodiment of a deck rail for supporting a deck according to the present invention; and Figures 19, 20 and 21 show side, end and top views of a third embodiment of a deck rail for supporting a deck according to the present invention;

DETAILED DESCRIPTION OF THE EMBODIMENTS

Figure 1 shows a deck 10 according to the present invention. It is formed by sandwiching together two sections; a generally flat upper sheet 12 and a generally flat lower sheet 14, each of a rectangular shape sized to match a conventional pallet. The two identical 20mm HDPE halves 12, 14 are heat welded together to form a single deck of 40mm in height. The inner surface of each half consists of a honeycombed layer, which is matched to that of the opposite half to define an internal honeycomb structure that gives the deck strength while reducing weight. As an alternative, one half of the deck could be provided with a honeycomb layer of twice the thickness, and mated to a smooth opposite half (i.e. without the honeycomb layer).

The honeycomb structure 16, shown in more detail in figure 2, comprises a series of internal ribs 18 arranged in a generally honeycombed (i.e. hexagonal array) pattern to provide the necessary thickness and rigidity to the deck at minimum weight. Some additional reinforcements are provided at points of particular stress, such as the centre 20 where weighty items are likely to be placed, at the corners 22 where impact damage is likely, and at the midpoints 24 of edges where stresses are likely to be greatest during lifting.

At each corner, a hollow space 26 is created -in this case this is done by omitting a wall between adjacent hexagonal cells, but the cell size may be sufficient depending on the honeycomb design. This space is used to accommodate an RFID tag 28 (shown in place in other corners) -i.e. a remotely readable identifier that can be scanned by a suitable radio-frequency unit and will return an identification code allowing the deck to be uniquely identified. By placing a tag at each corner, a scanning unit placed along one side of an entrance or exit for decks will come into close proximity to two tags regardless of the orientation of the deck, thereby allowing a degree of redundancy in the identification process. If the same number of tags are arranged differently, for example at the centres of each edge, then a scanning unit will only come into close proximity to one tag and the reliability of the system will suffer. Thus, a tag in each corner provides for the most efficient use of tags.

The upper and lower sheets 12, 14 are generally flat and thin, with stiffening ribs 30 on the outer surface of at least the upper sheet 12. Like ribs can be provided on the lower sheet 14 for additional rigidity if required, and may be oriented to match those on the upper sheet, or may be oriented perpendicularly, or otherwise. Alternatively, the lower sheet 14 can be externally smooth to ease the insertion of the blades of a forklift.

To assemble the deck, the two layers are sandwiched after applying an adhesive to the relevant surfaces of the honeycomb structure 16. Alternatively, the layers can be thermally welded together.

Figures 3 and 4 show views of the edge portion of the deck 10 of figure 1.

It can be seen that the edge of the deck is profiled with a semi-circular recess 32 that extends from each corner of the deck 10 towards a mid-point of each edge.

At the mid-point of each edge, as shown in figure 4, there is a flat un-recessed region 34 between the recess 32 extending from one corner and the recess 32' extending from the corner at the other end of that edge. This flat region 34 allows a barcode 36 or other machine-readable indicia to be affixed, to allow for manual scanning of the deck as an alternative or iii addition to RFID scorn;.

Figures 5 and 6 illustrate an alternative embodiment. Instead of a smooth arcuate profile to the recess 32 as in figures 3 and 4, there is a stepped profile to the recess 38. This could be formed by a suitable cutting tool applied to the edge of the deck 10, or by making up at least an edge portion of the deck 10 from a number of layered sheets. In the latter case, the edges of the layered sheets could further be provided with a dovetail section as illustrated by the dotted lines 40 in figure 5 to provide a form of barb to the profile of the recess 38.

Provision of the recess 32 or 38 provides a ledge against which shrink wrap applied around the deck 10 and any goods placed thereon can "key" to.

This makes the attachment of the shrink wrap much more secure, and makes it correspondingly more likely that the shrink wrap will remain in place for the entire journey. A deck with a smooth edge will not provide the same degree of retention and may therefore become separated from the load, with obvious consequences. In that case, the RFID tag and the bar code will also become separated from the load, thereby disrupting modern logistical practices. A stepped profile of figures 5 and 6 will provide a more positive retention of shrink wrap, and the barbed profile 40 of figure 5 even more so. However, the barbed edge is correspondingly more complex to manufacture and therefore the appropriate compromise between these factors should be sought.

Figures 7, 8 and 9 show a support on which a deck 10 as described in relation to figures 1 to 6 can placed. The support comprises a rail that can be fixed in place, in pairs on a suitable racking system. Each rail 50 is 7..

manufactured to a suitable length, typically 850-900mm and 120mm tall, out of a rectangular section steel profile. These can be arranged in pairs at a spacing either somewhat greater than the spacing of blades of a fork lift truck or somewhat narrower than that spacing, and a deck 10 can then be lowered onto the rails 50 by such a fork lift and subsequently raised therefrom when needed.

A cut-out 52 is provided to enable the rails to sit on existing shelf racking systems.

Figures 10, 11 and 12 show a corresponding form of deck rail 54 manufactured from a U-section tubing which can be formed from cold rolled steel section. This has a similar cut-out 56.

It may be necessary from time to time to store decks on a floor surface, and figures 13, 14 and 15 show a suitable platform on which to do so. This can be made up of hollowed steel section and steel plate and provides a base 58 on which are attached three box sections 60, 62, 64, spaced so as to receive a first blade of a fork lift truck between the rail 60 and the rail 62 and a second blade between the rail 62 and the rail 64. A deck 10 placed on such a support will thus be held a short distance above the ground, allowing a fork lift truck to lower the deck 10 onto the support and/or lift it off when necessary.

Figures 16, 17 and 18 show an alternative arrangement in which the base plates 58 is replaced with a series of lateral steel strips 66, 68, 70. This should provide a similar rigidity but with lesser usage of material.

In certain circumstances, it may be necessary to place or lift the deck from a variety of directions. Figures 19, 20 and 21 show a suitable arrangement for doing so. In this case, the base plate 58 is provided with a pattern of nine blocks 66 which define a 3 x 3 grid with blocks placed at the corners of the base plate 58, the mid-point of each side, and the centre of the base plate 58.

Accordingly, this can accommodate blades of a fork lift truck from two transverse directions and offers greater flexibility in use.

In the same way as is illustrated with respect to figure 16, 17 and 18, the base plate 58 of figures 13, 14 and 15 could be replaced with a pattern of lateral and longitudinal strips.

Alternatively, roller systems can allow decks to be loaded at one end of the vehicle and transported within the vehicle to a desired location so that further decks can be accommodated.

In the same way as is illustrated with respect to figures 16, 17 and 18, the base plate 58 of figures 19, 20 and 21 could be replaced with the pattern of lateral and longitudinal strips.

Through the present invention, a thin and lightweight deck can be provided as a practical and usable alternative to existing pallets. In this way, the transport of dead weight in the form of a pallet is both reduced and made more predictable in that the weight of the deck is essentially non-variable as compared to a wooden pallet. This means that, in general, a transportation vehicle can be loaded such that more efficient use is made of its available space and/or its available maximum gross weight.

Through the present invention, a thin and lightweight deck can be provided as a practical and usable alternative to existing pallets. In this way, the transport of dead weight in the form of a pallet is both reduced and made more predictable in that the weight of the deck is essentially non-variable as compared to a wooden pallet. This means that, in general, a transportation vehicle can be loaded such that more efficient use is made of its available space and/or its available maximum gross weight. In practice, this means that (on average) one pallet in 24 is transported free of charge as compared to existing wooden pallets. This is a substantial saving for the transportation industry resulting entirely from the elimination of non-value freight from a load.

Meanwhile, the usage of distribution centre racking space is maximised, and logistics tracking systems can be used more efficiently as the decks themselves are trackable by contrast to existing wooden pallets. The provision of suitable scanning portals at the entry and the exit points (for example) of distribution centres provides an accurate record of the arrival and departure of loads.

It will of course be understood that many variations may be made to the above-described embodiment without departing from the scope of the present nvcnt!on.

Claims

CLAIMS1. A deck for transporting a load, comprising a generally planar sheet having a circumferential edge, the edge having at least one elongate recess extending along at least part thereof.
2. A deck according to claim 1 in which the recess extends along a part of the edge only.
3. A deck according to claim 2 in which the sheet has a shape including corners, and the recess extends along the edge from a corner of the sheet towards a mid-point.
4. A deck according to claim 3 in which there are a plurality of recesses, one extending from each corner.
5. A deck according to claim 3 or claim 4 in which at least one edge includes a portion to which no recess extends.
6. A deck according to claim 5 in which the portion includes a visible indicia.
7. A deck according to claim 6 in which the visible indicia is a barcode.
8. A deck according to any one of the preceding claims in which the recess has an arcuate cross-section
9. A deck according to claim 8 in which the recess has a semi-circular cross-section
10. A deck according to any one of claims 1 to 7 in which the recess has a stepped cross-section.
11. A deck according to any one of the preceding claims in which the deck is substantially hollow.
12. A deck according to claim 11 in which the deck comprises upper and lower sections, joined.
13. A deck according to claim 12, being at least partly hollow.
14. A deck according to claim 13 in which the interior of the spacer has a honeycomb pattern.
15. A deck according to any one of claims 11 to 14 in which a remotely readable identifier is provided within a hollow interior space.
16. A deck according to claim 15 in which the remotely readable identifier is an RFID tag.
17. A deck for transporting a load, substantially as any one herein described with reference to and/or as illustrated in the accompanying figures 1 to 6.