GB2568541A

GB2568541A - Improvements in pallets

Info

Publication number: GB2568541A
Application number: GB1719263.4A
Authority: GB
Inventors: William Farley John
Original assignee: I Boxit Ltd
Current assignee: I Boxit Ltd
Priority date: 2017-11-21
Filing date: 2017-11-21
Publication date: 2019-05-22
Also published as: GB201719263D0

Abstract

A pallet 7 having planar top 8 and bottom 9 members held apart from each other by releasably attachable spacers 10, which may have a separator portion 11 and top 12 and bottom 13 fixing potions. The planar bottom member 9 may have at least one hole 38 to allow the wheels of a pallet truck to contact the ground. Preferred pallets have top 8 and bottom 9 planar members made from corrugated card with the same size and shape perimeter. Preferably, the constituent parts of the spacers 10 are formed of plastics and the separator portion 11 may be provided with blind tapped holes (18, figure 5) and a boss (25, figure 6). The top 12 and bottom 13 fixing potions could have cooperating threads (14 and 15, figure 6). The spacers 10 may be circular, square or, preferably, hexagonal in cross-section and can be configured to have a degree of rotation with respect to the top 8 and bottom 9 members.

Description

The invention relates to pallets for storing and transporting materials. The invention also relates to component parts for such pallets.

Background and Prior Art

Pallets are used the world over to store and transport goods in a stable fashion. A typical wooden pallet is illustrated in perspective form in Figure 1, generally indicated by 1. The pallet, which is shown in slightly exploded format for clarity, comprises a first set of wooden bearers 2 forming an upper surface, and a second set of lower bearers 3 forming a lower, ground-engaging surface. The two sets of bearers 2, 3 are held apart from each other by spacers 4, again made of wood. The spacers define one or more lifting cavities 5 into which the forks of a fork-lift truck or pallet truck can be inserted in order to move the pallet and its associated goods around.

The elements of wooden pallets are typically secured together by the use of nails 6.

Metal pallets are also known, sometime made of aluminium. A form of pallet (sometimes more correctly referred to as a “skid”) is also known, in which the complete structure is made of plastics.

There is a standard set of pallet sizes recognised under various national and international standards to facilitate the packing of containers and the use of pallets across the world. Common European sizes are 1200x800mm and 800x600mm, with the UK also using 1200x1000mm pallets. Smaller pallets of 400x600mm are also often used in a retail context.

One of the difficulties of present pallet design, especially in the case of the most common wooden pallets, is that they are both heavy and bulky. The weight (typically about 30 kg for a 1200 x 1000 mm wooden pallet) adds to transport costs, and makes them difficult to move about and to store when not in use. Their bulk poses particular problems in storage prior to, and after use.

Furthermore, pallets are relatively valuable and considerable logistics effort is expended on tracking pallets and returning them (eventually) to their owners. Also, for the shipment of certain types of goods, certain phytoprotection standards are required, leading to the need for heat treatment of wooden pallets before they can be used.

Pallets made of corrugated card are also known, such as those described in W02014003823 in which pallets are formed by folding and joining complex pre-cut sheets of card on a jig. US7007613 also describes a pallet formed of corrugated card, in which complex sheets of pre-cut card axe joined together in a jig, or by a machine tool by the use of integral tabs and slots.

It is among the objects of the present invention to attempt a solution to these and other problems.

Summary of the Invention

Accordingly, the invention provides a pallet comprising: a planar top member; at least one planar bottom member; and a plurality of spacers, each of said spacers being releasably attachable to said top member and said at least one bottom member to hold said top and bottom members parallel to each other in a spaced-apart configuration with respect to their plane surfaces.

Preferably said pallet comprises a single planar bottom member, and said top and bottom members have substantially the same size and shape perimeter. More preferably, said bottom member is provided with at least one hole passing therethrough to allow the wheels of a pallet truck, in use, to contact the ground though said hole(s).

In any such pallet, it is preferred that said top and bottom members are each of single piece construction, and made from a material selected from the group consisting of: plastics; card; corrugated card; fibreboard; plywood; metal; and glass fibre. More preferably, said top and bottom members are made from corrugated card.

In any pallet of the invention, is further preferred that the pallet comprises a spacer having: (a) a separator portion; (b) a top fixing portion; and (c) a bottom fixing portion; said three portions being configured to cooperate with each other to form a releasably-attachable spacer in which: said top planar member is releasably held between said separator portion and said top fixing portion; and said bottom planar member(s) is/are releasably held between said separator portion and said bottom fixing portion.

In such a pallet, it is further preferred that said spacer is configured such said separator portion can rotate about an axis perpendicular to the planar members when said top and bottom planar members are so held.

In any pallet of the invention, it is preferred that said spacer/s) are formed of plastics.

Also included within the scope of the invention is a spacer for a pallet, said spacer comprising: (a) a separator portion; (b) a top fixing portion; and (c) a bottom fixing portion; said three portions being configured to cooperate with each other to form a releasablyattachable spacer in which in its attached configuration: said separator portion and said top fixing portion define a gap therebetween; and said separator portion and said bottom fixing portion define a gap therebetween.

In such a spacer, in a preferred embodiment, said separator portion is provided with blind tapped holes to accept threaded top and bottom fixing portions.

Also in such a spacer, in an alternative preferred embodiment said separator portion is provided with a boss to locate said separator portion in a hole in a planar member of a pallet.

In any such spacer it is also preferred that its constituent parts are formed of plastics.

In any embodiment of a spacer of the invention having top or bottom fixing portions it is preferred that the upper face of a top fixing portion (in use) and/or the lower face of a bottom fixing portion (in use) is provided with a non-slip surface.

Brief Description of the Figures

The invention will be described with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a prior art pallet;

Figures 2-4 are exploded perspective views of embodiment of a pallet of the invention; Figures 5-8 illustrate embodiments of spacers forming part of a pallet of the invention; Figures 9A-9C illustrate the interaction between a fork of a pallet truck and a spacer of the invention;

Figures 10 and 11 illustrate in plan and cross-sectional view respectively an embodiment of a separator forming part of the invention;

Figure 12 is an exploded perspective view of an embodiment of a pallet of the invention; Figure 13-16 illustrate the interaction between a pallet truck and a pallet of the invention;

Figures 17A-17C illustrate plan views of planar members forming part of a pallet of the invention;

Figure 18 is an elevation view of a pallet of the invention; and

Figure 19 is a cross-section view of an embodiment of a spacer forming part of the invention.

Description of Preferred Embodiments

Figure 2 illustrates, in exploded perspective view, an embodiment of a pallet of the invention, generally indicated by 7. The pallet 7 comprises a single planar top member 8 and a single planar bottom member 9. The planar members 8, 9 are held together, one above the other, in a spaced apart relationship by means of spacers 10. In this embodiment, there are four spacers

10, located between each corner of the planar members 8, 9. Each spacer 10 comprises a separator portion 11, a top fixing portion 12, and a bottom fixing portion 13. The spacer 10 is releasably attachable to the two planar members 8, 9 by virtue of a projecting portion 14, 15 on the top and bottom fixing portions. Each projecting portion 14, 15 passes through a hole 16 in the top and bottom planar members respectively, to cooperate with corresponding cavities 17 in the spacers 11 and to be releasably held therewithin. Various configurations of spacer 10 will be described below.

The top and bottom planar members 8, 9 are formed of a material strong enough to support the weight of material intended to be transported on the pallet. It will be appreciated that the top planar member 8 is the member that needs to support the weight of the goods - the bottom member 9 primarily holds the spacers in their spaced-apart configuration, and resists bending forces transmitted through the spacers. In order to provide this differential strength, different materials could be used for the top and bottom planar members 8, 9 if required. Alternatively the members 8, 9 could be made of the same material, and two or more planar members used at the top, sandwiched together between the top fixing portions 12 and the separator portions

11.

The planar members could be formed e.g. from a material such as plastics (especially corrugated plastics), fibreboard, plywood, metal or glass fibre; but in a particularly preferred embodiment of the invention they are formed of corrugated card. The inventor has found that corrugated card having an Edge Compression Test (ECT) value of at least 20kN/m and preferably at least 25, 30, or even 40kN/m is particularly suitable. The ECT methodology is used across the corrugated card industry and is described in e.g. International Standard ISO 3037:2013. Such a material can be formed as e.g. a double wall corrugated card having inner, centre and outer liners of Kraft paper having a weight of at least 300 g/m², and preferably at least 400, 420, 440, or even 500 g/m². Sandwiched between these liners are layers of corrugated paper, referred to as “flutes”. The inventor has found that using the above liners with a C flute (128+10 flutes/m) formed of paper (such as recycled paper) with a weight of at least 120 g/m², and preferably at least 140 or even 150 g/m², in addition to a B flute (154+10 flutes/m) of the same weight, will provide adequate strength for a 1000kg load on the pallet.

An advantage of using corrugated board for the top and bottom member 8, 9 is that it makes the pallet light in weight, and also allows the top and bottom members to be readily recycled when the pallet is no longer needed.

The spacers 10 however, are preferably made from a durable material such as plastics. The inventor has found that high density polyethylene (HDPE) is a suitable material. The durability of the spacers makes the pallet significantly more resilient to damage during use than an all-cardboard pallet.

The combination of flat upper and lower members and repeatedly releasably attachable spacers offers overall advantages over the design of known pallets. Before or after use, the pallets may be stored in a disassembled configuration with the upper and lower planar members stacked on top of each other. The spacers can also be stored packed together, especially if they tessellate, thereby saving space. One difficult with the folded card pallets described above is that they are not only difficult to assemble (often requiring a jig), but that they cannot easily be disassembled without damaging the card, and even then the folds in the card make it difficult, if not impossible, for them to be stored easily.

Figure 3 illustrates, in exploded perspective form, a further embodiment of a pallet of the invention, generally indicated by 7. Features in common with the embodiment of Figure 2 are correspondingly numbered. This embodiment comprises a planar top member 8 and two planar bottom members 9a and 9b. This arrangement of pallet is particularly suitable for small pallets, and especially pallets where the intended load is not particularly heavy.

Figure 4 illustrates, again in exploded perspective form, a yet further embodiment of a pallet of the invention. Features in common with the embodiments of Figure 2 and 3 are again correspondingly numbered. This embodiment again comprises planar top 8 and bottom 9 members. The top and bottom members are held parallel to each other in a spaced-apart configuration by the use two spacers: the first spacer 10a comprises a separator portion 11a, two top fixing portions 12a, and two bottom fixing portions 13a; the second spacer 10b comprises a separator portion 1 lb, two top fixing portions 12b, and two bottom fixing portions 13b. The separator portions 11 and fixing portions 12, 13 are configured so that they are releasably attachable to each other, and therefore also to the top and bottom planar members 8, 9. Again, the separator portions 11a, lib are preferably made from a durable material such as plastics, e.g. HDPE.

Figure 5 illustrates, in cross-section view, an embodiment of a portion of a pallet of the invention comprising a spacer. The spacer has a separator portion 11, a top fixing portion 12, and a bottom fixing portion 13. In this embodiment, the spacer 11 is provided with a blind tapped hole 18 in each opposing face 21, 22 to receive a corresponding externally threaded projecting portion 14, 15 extending from a flange portion 19, 20 on each of the top and bottom fixing portions 12, 13. The projecting portions 12, 13 each pass through a hole 16 in respective top 8 and bottom 9 planar members. The length of each externally threaded projecting portion 14, 15 and corresponding blind tapped holes 18 is chosen such that when the threaded projecting portions 12, 13 are screwed into the holes to their fullest extent, the flange portions 19, 20 are spaced apart from the opposing faces 21, 22 of the separator portion 11 to an extent that they lightly grip the corresponding top 8 and bottom 9 planar members. The elements in Figure 5 are illustrated in a slightly spaced-apart configuration, for clarity. Where the top and bottom planar members 8, 9 are made (as illustrated in Fig. 5) from corrugated card, this feature prevents the spacers from damaging and weakening the card through crushing when the spacers are tightened into position. Furthermore, the light grip on the planar members 8, 9 also allows for a degree of rotation of the spacers, as will be discussed below. Each of the top 12 and bottom 13 fixing portions may also be provided with an engagement feature to allow torque to be applied to the members via a tool to facilitate attaching and detaching the spacers from the top and bottom planar members. In this embodiment the engagement feature is in the form of a recessed hexagonal hole 23 to allow engagement with a corresponding hexagonally-shaped tool. Other engagement features are also contemplated, such as a pair of recessed holes to receive a tool having corresponding pins. It can also be seen in Figure 5, that the diameter of the flange portions 19, 20 is less than the outside diameter of the separator portion 11. The inventor has found that, when using corrugated card as the planar member, it is possible to reduce the size of the area of contact between the flange portions 19, 20 and the planar member to less than the corresponding size of the separator portion in order to reduce costs of materials. Routine trial-and-error can determine the minimum area of contact for any given grade of material used for the planar members.

Figure 19 illustrates, in cross-section view a further embodiment of a top 12 fixing portion forming part of an embodiment of the invention. In this embodiment, the projecting portion is provided with a shoulder 48 that can abut the face 21 of the separator portion 11, thereby preventing the flange 19 from crushing the planar member 8 when the top fixing portion is screwed into place. The height 49 of the shoulder is chosen for a particular thickness of planar member 8 such that when screwed into position, the top fixing portion grips the planar member whilst preferably allowing some relative rotational movement between the elements as discussed herein. Furthermore, the flange 19 is preferably provided with a non-slip upper face 50 by the provision of e.g. protruding pips 51 or a roughened surface 52. Such a non-slip surface resists assembled pallets from moving relative to each other when stacked together in the absence of a load.

It will be appreciated that the additional features described for the top fixing portion 12 may also be applied to the bottom fixing portion 13.

Figure 6 illustrates, in cross-section view, a further embodiment of a portion of a pallet of the invention comprising a spacer. Like elements described previously are correspondingly numbered. In this embodiment, the separator portion 11 is a cylinder (e.g. circular or hexagonal cylinder) having a through hole 24 extending between opposing top 21 and bottom 22 faces of the separator portion 11. Surrounding each end of the hole is provided a boss 25 extending away from the faces 21, 22. The height of each boss is chosen to be slightly less than the thickness of material (e.g. card) to be used for the top and bottom planar members 8, 9. The top fixing portion 12 is provided with an externally threaded projecting portion 14, and the bottom fixing portion 13 is provided with a cooperating internally threaded projecting portion 15. It will be appreciated of course that the top and bottom portions could have either the externally or internally threaded projecting portions. In this embodiment, to attach the spacer 10 to the top and bottom planar members, the top 12 and bottom 13 fixing portions are screwed together until their flange portions 19, 20 abut the faces 21, 22 of the separator portion 11 and thereby lightly grip each of the planar members 8, 9.

Figures 7 and 8 illustrate, in cross-sectional view, a further embodiment of a spacer 10 forming part of a pallet of the invention. Like elements are again correspondingly numbered. In this embodiment, the separator portion 11 is provided with a profiled hole 26 extending between opposing faces 21, 22. Each of the top 12 and bottom 13 fixing portion comprises a flange element 19 and a projecting element 14, said element 14 itself comprising two resiliently deformable arms 27 having a tapered end 28 leading to an extending rim 29. To attach the spacer 10 to the planar members 8, 9, the projecting portions 14 are inserted through holes 16 in the planar members, and into end of the hole 26 in the separator portion 11. As illustrated at the bottom of Figure 7, the interaction of the tapered portion 28 with the edge of the hole 26 causes the arms 27 to bend inwardly and allow the extending portion 14 to be pushed into the hole 26. Upon further pressure, the rim feature 29 of the arms 27 enters a recess 30 around the hole 26 to lock the fixing portion in place, as illustrated in Figure 8. The length of the arms 27 and the position of the recess 30 may be chosen such that when the spacer is in its connected configuration, the inward facing faces of the flanges 19 lightly grip the planar members against the faces 21, 22 of the separator portion 11.

Holes 31 communicating between an outside face of the separator 11 and the recess 30 may be provided to allow a tool (e.g. a rod) to be used to deform the arms 27 inwardly, thereby allowing the spacer to be detached from the planar members 8,9.

Figures 9A to 9C illustrate a technical benefit of the spacer 10 design allowing some limited rotation of the separator portion 11 with respect to the planar members 8, 9, and also the effect of different shaped separator portions. Each figure represents a plan view of a spacer and a portion of a fork 32 of a forklift or pallet truck. In the illustrations, the fork 32 is misaligned within the pallet, which commonly occurs in use, such that it impacts on the separator 11. The inventor has found that with circular cyclindrical separators as illustrated in Figure 9A, such an impact can cause the fork 32 to damage the separator, as there is insufficient friction between the separator a and the fork 32, to cause the separator to rotate; this can result in the separator being damaged, at least on its surface. However, the use of flat-sided separators such as those shown in Figures 9B and 9C allows such an impact to result in rotation of the separator f f, thereby reducing damage. The inventor has found that a hexagonaf cylinder, such as illustrated in Figure 9C is particularly effective at reducing damage fohowing such an impact.

Figures f0 and 11 illustrate in plan and cross-sectional view respectively a particularly preferred embodiment of a separator f f forming part of the invention. The cross-section of Figure 11 is taken through the line A-A of Figure f0. The separator f f has the generaf form of a hexagonaf cyfinder, formed with an outside waff 33 connected to an inner, centraf, circufar cyfinder 34 by radiaf webs 35 extending from the vertices of the hexagonat outer wah 33. As shown in Figure 11, a further horizontal web 53 is also provided approximately halfway down the spacer f f connecting the centre region of the outside wah 33 to the centre region of the cyfinder 34. On the inside surface of each open end of the cyfinder 34 is provided an internaf threaded region 36 extending part-way down the cyfinder, as described in the discussion of Figure 5. In preferred embodiments, the separator 11 is of one-piece pfastics construction, preferabfy injection-moufded, and made of a durabfe materiaf such as HDPE.

In preferred embodiments of spacers 11 forming part of the invention, the diameter (or effective diameter) 54 of the spacer is between 50 and 200 mm, preferably between 75 and 150mm, such as 100mm. Also, the height 55 of the spacers 11 is typically in the range of 60 to 175mm, for 125, 100, 90 or 75mm. Where a blind thread 36 is used to limit the movement of a top 12 or bottom 13 fixing portion, it is preferred that the thread depth 56 is between about 20 and 40 mm, for example 25 mm.

Figure 12 illustrates, in exploded perspective view, a preferred embodiment of a pallet of the invention. Like elements described above are numbered accordingly. This embodiment has a top planar member 8, preferably made from corrugated card, and having rounded corners. The top member 8 is also provided with nine holes 16 spaced apart in a rectangular matrix, and each sixed to accept a protruding member 14 from a corresponding top fixing portion 12. The bottom planar member 9 has the same features as the top member 8, but in addition is provided with two rectangular apertures 38 sized and shaped so as to allow the wheels of a pallet truck to engage with the ground through the apertures 38. The apertures 38 preferably also have rounded internal corners. This is discussed and illustrated in more detail below.

The top 8 and bottom 9 members are held apart by corresponding nine separators 11, only seven of which are illustrated om Fig 12, for sake of clarity. The separators are hexagonal in form, as illustrated in Figures 10-11.

As an aid to explanation, Figures 13 and 14 illustrate in elevation and plan view respectively a known pallet truck, generally indicated by 39 suitable for use with a pallet of the invention. The truck 39 is provided with a pair of forks 32 that may be placed between upper and lower planar members of a pallet to be lifted. By operation of the handle 40 and (usually) an associated hydraulic mechanism, the forks can be moved between a lower and an upper position, as illustrated, to enable a pallet to be moved around. One end of the truck 39 is provided with a pair of wheels 41, and the distal end of each fork is provided with a groundengaging roller 42. When lifting a pallet, the rollers 42 engage with the ground, providing support to the truck 39 and pallet.

In view of this mode of operation, and as illustrated in Figure 15, this is the reason why preferred embodiments of pallets 7 of the invention are provided with an aperture 38 through which the rollers 42 of a pallet truck 39 may engage the ground. Such an aperture is not required if the pallet 7 is to be lifted by a fork-lift truck in which the forks do not have such a ground-engaging roller, but are cantilevered, with the truck itself being provided with a counter-weight to prevent toppling. In Figure 15, the top planar member 8 is omitted, to allow the bottom planar member 9 to be more clearly seen.

Figure 16 illustrates, and in a form analogous to that of Figure 15 a bottom planar member 9 of a pallet of the invention in which two apertures 38 are provided. This provides additional stability to the bottom member while allowing a pallet truck to be used from any side of the pallet. Corresponding elements previously described are numbered correspondingly.

Figures 17A-17C illustrate, in plan view, various embodiments of planar members 8, 9 suitable to form a pallet 7 of the invention. Like elements described previously are correspondingly numbered. Figure 17A illustrates a planar member suitable for use as a top planar member 8, or a bottom planar member where a forklift truck is to be used. As discussed previously, if increased strength is required, more than one corrugated card planar member can be used on the top of a pallet, the multiple members sandwiched together between the top fixing portions 12 and the corresponding separator portions 11.

Whilst the inventor has found that corrugated card is surprisingly resistant to the expected negative effects of a damp atmosphere, it is also envisaged that such card can be given a moisture-repellent coating if required.

Figures 17B and 17C are suitable for use as bottom planar members.

Figure 18 illustrates, in elevation and expanded detail view, an embodiment of a pallet of the invention, generally indicated by 7. Like elements described previously are correspondingly numbered. In this embodiment to top and bottom planar members 8, 9 are made from double wall corrugated card having upper 43, lower 44 and centre liners 45, and a C flute 46 and B flute 47 as described above. Also in this embodiment, the height H2 of the flange of the bottom fixing portion 13 is greater than the height of the flange of the top fixing portion 12. This is to allow additional clearance below the underside of the bottom planar member 9, to help protect it from moisture ingress in the event that it is used on damp flooring. It is envisaged that the height Hl of the top flange would be approximately 3mm, perhaps in the range of 2-5mm. The height H2 of the bottom flange would be approximately 10mm, perhaps in the range of 2-15mm. The separation H3 between the inner faces of the top and bottom planar members 8, 9 will typically be in the range of 60-175 mm, with standard sizes of 125, 90 or 75mm being most likely.

Claims

1. A pallet comprising:

a planar top member;

at least one planar bottom member;

and a plurality of spacers, each of said spacers being releasably attachable to said top member and said at least one bottom member to hold said top and bottom members parallel to each other in a spaced-apart configuration with respect to their plane surfaces.

2. A pallet according to Claim 1 comprising a single planar bottom member, and wherein said top and bottom members have substantially the same size and shape perimeter.

3. A pallet according to Claim 2 wherein said bottom member is provided with at least one hole passing therethrough to allow the wheels of a pallet truck, in use, to contact the ground though said hole(s).

4. A pallet according to any preceding claim wherein said top and bottom members are each of single piece construction, and made from a material selected from the group consisting of:

plastics;

card;

corrugated card;

fibreboard;

plywood;

metal; and glass fibre.

5. A pallet according to Claim 4 wherein said top and bottom members are made from corrugated card.

6. A pallet according to any preceding claim comprising a spacer having:

(a) a separator portion;

(b) a top fixing portion; and (c) a bottom fixing portion;

said three portions being configured to cooperate with each other to form a releasablyattachable spacer in which:

said top planar member is releasably held between said separator portion and said top fixing portion; and said bottom planar member(s) is/are releasably held between said separator portion and said bottom fixing portion.

7. A pallet according to Claim 6 wherein said spacer is configured such said separator portion can rotate about an axis perpendicular to the planar members when said top and bottom planar members axe so held.

8. A pallet according to any preceding claim wherein said spacer(s) are formed of plastics.

9. A spacer for a pallet according to any preceding claim, said spacer comprising:

(a) a separator portion;

(b) a top fixing portion; and (c) a bottom fixing portion;

said three portions being configured to cooperate with each other to form a releasablyattachable spacer in which in its attached configuration:

said separator portion and said top fixing portion define a gap therebetween; and said separator portion and said bottom fixing portion define a gap therebetween.

10. A spacer according to Claim 9 wherein said separator portion is provided with blind tapped holes to accept threaded top and bottom fixing portions.

11. A spacer according to Claim 9 wherein said separator portion is provided with a boss to locate said separator portion in a hole in a planar member of a pallet.

12. A spacer according to any of Claims 9 to 11 wherein its constituent parts are formed of plastics.

13. A spacer according to any of Claims 9 to 12 wherein the upper face of a top fixing portion and/or the lower face of a bottom fixing portion is provided with a non-slip surface.