GB2592663A

GB2592663A - Collapsible pallet

Info

Publication number: GB2592663A
Application number: GB2003253.8A
Authority: GB
Inventors: Albert Cummins Graham; John Cummins Christopher
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-03-06
Filing date: 2020-03-06
Publication date: 2021-09-08
Anticipated expiration: 2040-03-06
Also published as: GB2592663B; GB202003253D0

Abstract

A modular collapsible pallet wherein the footprint width is reduced when the pallet is moved from an open to a closed configuration. The pallet comprises two end caps 600 that are releasably connected to two outer stringers 500 and an inner stringer (300, fig 1b); load baring slats 400; and locking struts (700, fig 1b). Wherein one end of each slat is attached to an outer stringer, and the distal end is slidably mounted to the inner stringer, wherein when the pallet is moved to a closed position the slats attached to opposing stringers slide next to each other. To collapse the pallet, locking struts that are connected to the undersides of inner and outer stringers locking the pallet in the open configuration are removed together with the end caps. The end caps are repositioned longitudinally either side of the inner stringer, and the outer stringers are manually pushed together, causing a telescopic movement as the slats. When the pallet is closed the struts are secured to the outer stringers locking the pallet in the closed position and securing the end caps within the pallet (fig 2a-b). Preferably the pallet has 4-way lifting access, quick release fasteners, and replaceable parts.

Description

Collapsible Pallet

DESCRIPTION

This Section provides the following sub-sections: Invention Title: page 1 Justification for the Invention: page 1 Pallet History: page 2

Design Statement page 3

Introduction of the Drawings: page 4

Preferred Embodiment with Summary page 7

Inventors: page 9

References Cited: page 9

INVENTION TITLE: " Collapsible Pallet" Typical definition as taken in part from Wikipedia website: Collapsible ( kel&parbel) (of an object) able to be configured into a smaller shape or size for ease of storage.

JUSTIFICATION FOR THE INVENTION: Food & Beverage Trade Show Exhibitors amongst others generally have their Booth / Stand Displays and Product containerised on a GMA compliant Pallet for easy transportation to and from their Trade Show Booth.

GMA Pallet size 46"x 40"x 4 3/4"[ 1219 mm x 1016 mm x 121 mm] Trade Show Booths typically provide a 10' x 10' [ 3048 mm x 3048 mm clear floor space.

The use of Pallets in this environment are typical due to their availability and proven efficient and safe way of material handling; however their use comes with attendant problems namely: once unloaded, the fixed parameters of the GMA Pallet makes it impractical to store the Pallet within the typical Trade Show Booth Area. Additionally the management of the Pallet requires a third party Storage-Delivery Service which brings with it further inherent problems: namely: the associated logistics of the Pallet 'delivery-removal' cycle can cause unacceptable delays both at Trade Show Set-Up & especially Pallet delivery and collection when Clearing-Up at the end of the Trade Show.

A need therefore exists for a GMA footprint compliant pallet that can be configured for local storage within the Exhibitors Trade Show Booth.

PALLET HISTORY: A pallet is typically a flat wooden transport structure, which supports goods in a stable fashion, often secured with strapping, shrink wrap and more recently associated collar containers, whilst being lifted by a forklift, a pallet jack, front loader, jacking device or a crane.

This invention reconsiders the Standard GMA American Pallet; The Standard GMA Pallet consists of 15 wooden components namely: 3 notched Stringers, 2 End Boards with 5 Middle Boards which form a Top Deck, 2 End Boards with 3 Middle Boards which form the Bottom Deck. The Stringers & boards are configured to provide 4-Way Lifting access by Forklift, Pallet Truck equipment While most pallets are wooden, pallets can also be made of plastic, metal, paper, and recycled materials. Each material has advantages and disadvantages.

This invention proposes a Collapsible Pallet with a GMA compliant footprint consisting of 23 plastic molded components namely: 3 notched Stringers with 16 Slats and 2 End Caps form a Top Deck and 2 Struts together with the End Caps and Stringers form, in part, the Bottom Deck.

The Stringers & End Caps are configured to provide 4-Way Lifting access for Forklift and Pallet Truck equipment The proposed Stringers & Slats Assembly can be manually collapsed in Width to provide a reduced foot print; providing a more compact assemble with manual handling, shipping and storage benefits.

GMA stands for the Grocery Manufacturers Association, since 1908 the GMA 's main purpose is to help mobilize packaged consumer goods around the USA and have recommended a standard pallet footprint of 48"x40". to make distribution operations smoother, Pallets of these dimensions are now commonly referred to as GMA pallets and are widely used in North America and beyond. In fact over 30% of pallets produced in the US each year use the recommended GMA pallet footprint. The International Organization for Standardization (ISO) also recognizes the GMA pallet and has approved it as one of the top 6 pallet dimensions globally.

DESIGN STATEMENT:

This DESIGN consider a COLLAPSIBLE PALLET comprising top and bottom surfaces together with support elements that are manually collapsible from a loadable OPEN configuration to a compact CLOSED configuration to provide a reduced footprint for manual handling, shipping and storage.

The difference between the OPEN & CLOSED configuration is defined herein as the STROKE where the STROKE defines the relational geometry of the translatable parts.

The Top Surface comprises a series of SLATS that together with the STRINGERS can be manually translated in WIDTH to provide either an OPEN or CLOSED configuration within the limits of the STROKE.

The SLATS are retained and supported along the LENGTH of the PALLET by three featured STRINGERS as appropriate.

The STRINGERS are supported across the WIDTH of the PALLET by a pair of detachable featured END CAPS that are secured in place.

The STRINGERS provide both TOP & BOTTOM surfaces. The BOTTOM surfaces providing load sharing contact with the floor.

The END CAPS provide additional TOP & BOTTOM surfaces. The BOTTOM surfaces providing additional load sharing contact with the floor The OPEN configuration is retained in position by a pair of detachable STRUTS that are secured in place on the underside of the STRINGERS.

The CLOSED configuration is retained in position by the same pair of detachable STRUTS which are re-positioned and secured in place on the underside of the STRINGERS.

The detachable END CAPS & STRUTS are secured in place with QUICK RELEASE 1/4 TURN FASTENERS.

By design; the END COVERS can be stored within the CLOSED configuration.

Note: Upper Case Text denotes KEY Design Features and Components.

Core design principles have been fixed at: Pallet LENGTH at the GMA standard of 48" [1220 mm] Pallet WIDTH [ OPEN configuration] at the GMA standard of 40" [1016 mm] FOOT PRINT at the GMA standard by definition equals 48"x 40".

Pallet WIDTH [ CLOSED configuration] by design at 585 mm [ 23" ] STROKE by design equals 431 mm [17"]

INTRODUCTION OF THE DRAWINGS:

FIG. la illustrates an isometric TOPSIDE view exemplary of a GMA foot print compliant PALLET in the loadable OPEN Configuration constructed in accordance with the present invention; FIG. lb illustrates an isometric UNDERSIDE view exemplary of a GMA foot print compliant PALLET in the loadable OPEN Configuration constructed in accordance with the present invention; FIG. 2a illustrates an isometric set of TOPSIDE and UNDERSIDE views exemplary of a GMA foot print compliant PALLET in the manual handling CLOSED Configuration constructed in accordance with the present invention; FIG. 2b illustrates an isometric view exemplary of a GMA foot print compliant PALLET in the CLOSED Configuration orientated for manual lifting constructed in accordance with the present invention; FIG. 3 illustrates an isometric view exemplary of the INNER-STRINGER constructed in accordance with the present invention; Significant features of INNER-STRINGER 300 are: 3A -pallet truck tyne access cut-out features 38 -stringer joint mating feature with END CAP 600 3C -strut location feature with STRUTS 700 in OPEN configuration 3D -strut location feature with STRUTS 700 in CLOSED configuration 3E -slat translation guide for SLATS 400 3F -backstop feature to constrain SLAT 400 in OPEN configuration 3G -lightening /strengthening rib array -typical molding feature.

FIG. 4 illustrates an isometric view exemplary of the SLATS constructed in accordance with the present invention; Significant features of SLAT 400 are: 4A -dovetail beam cross section providing interlocking constraint of the plurality of SLAT 400 with OUTER-STRINGER 500 and translation guidance with INNER-STRINGER 300 during the translation of the OPEN and CLOSED configurations.

48 -backstop oblique face which in conjunction with INNER-STRINGER 300 feature 3F limits the translation from the CLOSED to OPEN configuration.

4C -backstop oblique face which in conjunction with apposing OUTER-STRINGER 500 feature 5J limits the translation of the OPEN to CLOSED configuration. Additionally provides a latching interlock to stiffen the CLOSED configuration.

4D -holes which align with OUTER-STRINGER 500 hole features 5G to accept fasteners 900.

4E & 4F -lightening /strengthening rib array -typical molding feature.

FIG. 5 illustrates an isometric view exemplary of the OUTER-STRINGERS constructed in accordance with the present invention; Significant features of OUTER-STRINGER 500 are: 5A -pallet truck tyne access cut-out features 58 -load sharing feature to mate with END CAPS 600 5C -dove tail location constraint feature for END CAP 5D -strut location feature to mate with STRUTS 700 in OPEN configuration 5E -strut location feature to mate with STRUTS 700 in CLOSED configuration 5F -slat location feature to mate with SLATS 400 5G -hole feature for FASTENERS 900 5H -stacking post/box location mate features on top deck 5J -stacking post/box location mate features on bottom deck 5K -backstop feature to mate with SLAT 400 in CLOSED configuration 5L -backstop feature to constrain END CAP 600 in CLOSED configuration 5M -lightening / strengthening rib array -typical molding feature 5N -finger grip lifting point for manual handling in CLOSED configuration FIG. 6 illustrates an isometric view exemplary of the END CAPS constructed in accordance with the present invention; Significant features of END CAP 600 are: 6A -fork lift tyne & pallet truck access cut-out with lead-in ramp features 68 -load sharing feature to mate with OUTER-STRINGERS 500 6C -joint mating feature with INNER-STRINGER 300 6D -dove tail location constraint feature with OUTER-STRINGERS 500 6E -stacking post/box location mate features on top deck 6F -stacking post/box location mate features on bottom deck FIG. 7 illustrates an isometric view exemplary of the STRUTS constructed in accordance with the present invention; Significant features of STRUT 700 are: For the OPEN configuration: 7A -dove tail location constraint feature mates with INNER-STRINGER 300 feature 3C.

78 -dove tail location constraint feature mates with OUTER-STRINGERS 500 feature 5D.

7C -load bracing feature to mate with OUTER-STRINGERS 500 800 -QUICK RELEASE FASTENERS lock the configuration as an assembly For the CLOSED configuration: 7A -dove tail location constraint feature mates with OUTER-STRINGERS 500 feature 5D.

78 -dove tail location constraint feature mates with OUTER-STRINGERS 500 feature 5E.

7C -NOT USED in the CLOSED configuration 800 -QUICK RELEASE FASTENERS lock the configuration as an assembly FIG. 8 illustrates an isometric view exemplary of the QUICK RELEASE FASTENERS preferred in accordance with the present invention; Significant features of the QUICK RELEASE FASTENER ASSEMBLY are: 8A -thumb screw manual turn faces 88 -quick release interface feature 8C -slot feature for utilizing a lever turning tool 8D -rotational limit feature mates with features on the END CAPS and STRUTS.

FIG. 9 illustrates typical FIXINGS preferred in accordance with the present invention; Significant considerations of the CONSTRUCTION FASTENERS 900 are: 901 -preferably proprietary items that function with a push fit action [ Roll Pins, Wedges or similar] or expansive fit [ Snap, Click Rivets or similar] 902 -If thread forms are required then the thread so formed should, where practical, be in the part best suited to accept re-threading with inserts or similar should the need arise.

FIG. 10 illustrates an isometric TOPSIDE view exemplary of a STANDARD GMA PALLET that is referenced throughout the present invention provided for comparative information only.

PREFERRED EMBODIMENT

The following description is considered that of the preferred embodiment only Modification of the invention will occur by those skilled in the art of Design for Manufacture (DFM), Design for Assembly (DFA), Value Engineering (VE) or similar and by those who make or use the invention. Therefore, it is to be understood that the embodiments shown in the drawings and as described herein are merely for illustrative purposes and not intended to limit the Scope of the invention, which is defined by the claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents.

Modification of the invention could include: special fasteners, ultrasonic welding of components, molded in drainage features, radius corners /edges to improve handling or similar.

All Assemblies & Components are referenced in the following format; the Numeric Ref defines the Assembly or Component ( e.g.: Assembly, 100, 200... or Component 300... thru to 900) with the Numeric-Alpha Ref defining the Feature within the Assembly or Component: ( e.g.: Feature A 'within Component 300; defined as 300A but abbreviated to 3A, 38, 3C...thru to 9A... for clarity) For continuity; all essential Assemble /Component and Features are numbered the same throughout this document Referring now to the drawings which show the preferred embodiment of the invention, and particularly to: FIG la & Fig lb: Illustrating a modular PALLET ASSEMBLY 100 consisting of a plurality of SLATS 400, OUTER STRINGERS 500, INNER-STRINGER 300, END CAPS 600, STRUTS 700 to form a top and bottom deck shown here in the OPEN configuration available for loading and transporting goods.

FIG 2a &Fig 2b: Illustrating a modular PALLET ASSEMBLY 200 consisting of the same plurality of SLATS 400, OUTER STRINGERS 500, INNER-STRINGER 300, END CAPS 600, STRUTS 700 to form a top and bottom deck now shown in the CLOSED configuration available for compact manual handling, storage and shipping.

The top deck consists of a plurality of SLATS 400 where feature 4A interlocks with the OUTER-STRINGERS 500 through the geometry of slots 5F utilizing fixings 900 (not shown) in conjunction with hole features 4D, 5G.

The plurality of SLATS 400 further interlock with the INNER-STRINGER 300 through the geometry of slots 3D which both guide and constrain the plurality of SLATS 400 during the translation of the OPEN and CLOSED configurations.

Both OUTER STRINGERS 500 & INNER STRINGER 300 further interlock with a plurality of END CAPS 600 through features 5B, 5C, 802, 38 & 802 mating with features 68, 6D & QUICK RELEASE FASTENERS 800.

For the OPEN configuration both OUTER STRINGERS 500 & INNER STRINGER 300 further interlock with a plurality of STRUTS 700 through STRINGER features 5D & 3C mating with STRUT features 7A, 78 & 7C thru' fasteners 800.

For the CLOSED configuration both OUTER STRINGERS 500 & INNER STRINGER 300 are locked in this configuration with the same plurality of STRUTS 700 through STRINGER features 5D & 3D mating with STRUT features 7A & 78 thru' fasteners 800.

The QUICK RELEASE FASTENER ASSEMBLY 800 comprises a molded THUMB SCREW HEAD 801 with a CIRCLIP RETAINER 802 and RECEPTACLE 803 where the RECEPTACLE is preferably threaded on the outside diameter to provide adjustment for the quick release function.

CONSTRUCTION FASTENERS 900 are preferably proprietary items that comply and function with conventional powered assembly hand tools. Preferred quantity is 32 in totaL This concluded the 'DESCRIPTION OF THE PREFERRED EMBODIMENT' TO SUMMARISE: A plurality of 5 individual molded components, totalling 23 parts plus fasteners, are configured to provide a usable rectangular PALLET structure that can be manually COLLAPSED from a loadable OPEN configuration to a compact unloaded CLOSED configuration with a reduced foot print for compact manual handling, shipping and storage.

The OPEN configuration to a CLOSED configuration is achieved by manually: unlocking 10x QUICK RELEASE FASTENERS, removing 4x COMPONENTS, manually translating the width inwards to LIMIT STOPS, repositioning 4x COMPONENTS and re-locking 4x QUICK RELEASE FASTENERS. Note:

The QUICK RELEASE FASTENERS are retained within the HOST COMPONENTS to minimise the loose part count INVENTORS: Graham A Cummins (UK) with: Christopher John Cummins (USA) ASSIGNEE: Christopher John Cummins (USA) & Jennifer Jane Cummins ( USA)

REFERENCES CITED:

1939 -US2,178,646 [ original wood design]; 1950-US2,503,022 [repairable 1957 -U52,952,433 j folding J; 1975 -US3,878,796 [Modular] 1992-US5,101,737 [ snap fit]; 1995-US5,440,998 [ repairable] 1996-US5,579,701 [ knock down]; 1999 -US5,941,179 [x3 Mouldings] 2001 -G82335409 [ kit form]; 2002 -US6,837,170 [ modular] 2016 -GB2537610 [ configurable]; 2017 -GB2545150 j composite J; among others.

Claims

WHAT IS CLAIMED IS: 1: This invention relates to pallets. It is concerned with a modular essentially rectangular PALLET assembly, the parts of which are also modular comprising top and bottom surfaces together with support elements that are COLLAPSIBLE in WIDTH from a loadable OPEN configuration to a compact unloaded CLOSED configuration.

2: A collapsible pallet as set forth in claim 1, wherein the said pallet in the OPEN configuration provides a GMA standard footprint assembly.

3: A collapsible pallet as set forth in claim 1, wherein the said pallet in the OPEN configuration can be manually collapsed in WIDTH to provide a CLOSED configuration to provide a reduced foot print assembly for compact manual handling, shipping and storage.

4: A collapsible pallet as set forth in claim 1, wherein the said pallet in the OPEN configuration provides 4-Way PALLET lifting access for material handling devices such as industrial forklifts and pallet trucks.

5: A collapsible pallet as set forth in claim 1, wherein the said pallet comprises at least a plurality of five individual the moulded components with associated retained quick release fasteners and permanent construction fasteners.

6: A collapsible pallet as set forth in claim 1, wherein the said pallet provides manual translation of width from OPEN to CLOSED to OPEN configurations as appropriate.

7: A collapsible pallet as set forth in claim 5, wherein the said pallet comprises at/east four removable components with associated retained quick release fasteners.

8: A collapsible pallet as set forth in claim 5, wherein the said pallet in the CLOSED configuration provides storage of at least two of the removable components within the CLOSED configuration.

9: A collapsible pallet as set forth in claim 7, wherein the said pallet in the CLOSED configuration uses at least two of the removable components to retain and lock the CLOSED assembly for compact manual handling, shipping and storage.

10: A collapsible pallet as set forth in claim 5, wherein the said pallet includes mating sections which form the interconnection between the various components, while at the same time readily allowing for the initial assembly, the 'in-service translation' of configurations and the disengagement of components for repair by replacement 11: A collapsible pallet as set forth in claim 5, wherein the said pallet includes location features which serve to align and stack another Pallet or Pallet Collar or similar mounted thereon.12: A collapsible pallet as set forth in claim 5, wherein the said pallet features provide for replacement of damaged components.13: A collapsible pallet as set forth in claim 5, wherein the said pallet comprises weight lightening features derived through Engineering Analysis procedures.14: A collapsible pallet as set forth in claim 5, wherein the said pallet comprises strengthening features derived through Engineering Analysis procedures.15: A collapsible pallet as set forth in claim 5, wherein the said pallet contains an effective amount of UV stabilizer.16: A collapsible pallet as set forth in claim 5, wherein the said pallet components may contain reinforcements which can be axially or biaxially oriented at the time of manufacture, such as fiberglass, rovings, mesh, bar, plate webs or similar to enhance the structural strength.17: A collapsible pallet as set forth in claim 5, wherein the said pallet provides for dedicated Branding /Logo features.