GB2600365A

GB2600365A - A modular system for constructing a pallet

Info

Publication number: GB2600365A
Application number: GB2201728.9A
Authority: GB
Inventors: Julian Griffiths Denzil
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-11-07
Filing date: 2016-11-07
Publication date: 2022-04-27
Anticipated expiration: 2036-11-07
Also published as: GB202201728D0; GB2600365B

Abstract

A modular system for constructing a pallet 1, the system comprising: a plurality of slats 11, and a plurality of beams 3. Each beam 3 has a first end 25 which can interlock with the end of another similar beam, and one or more slat recesses 9. In use, four beams 3 can be interlocked to form a pallet frame. Each slat recess 9 can receive a portion of a slat 11. In use, a slat 11 can be mounted on and extend between at least two of said beams 3 to form a side wall 60 and/or deck 4 of a stillage (55, fig 5). A pallet like base is connected to two upwardly extending posts with slats passing between the arms to form a side wall. An upwardly extending arm interlocks with a pallet like base by sliding in a direction parallel to the surface of the pallet.

Description

A Modular System for Constructing a Pallet

Field of the Invention

The present invention concerns a modular construction system, and in particular a system for constructing a pallet to be used for storing and transporting goods. The invention also concerns methods of constructing a pallet using such a system and reconfigurable pallets having a modular construction.

Background of the Invention

A pallet typically comprises a base having a deck on which goods to be stored or transported can be stacked. However, the shape of some goods means they are unsuitable for stacking on such an open-sided pallet.

As an alternative to a pallet a stillage may be used. A stillage may comprise a base and one or more side walls or posts configured to support and retain goods within the footprint of the stillage.

As a result of the side walls or posts stillages may occupy a large amount of space when not in use. In order to reduce the space occupied by a stillage, it known to have a stillage with pivotally mounted or removably mounted corner posts. Wien the stillage is not in use the posts can be folded down or removed to reduce the amount of space occupied by the stillage. However, such stillages may still occupy a significant amount of space and it would be advantageous to provide a stillage with a more compact stored form.

The form of a stillage may vary depending on the nature of the goods to be stored or transported and a wide variety of stillages are known to the industry. In order to safely store or transport a wide variety of goods it may be necessary for a user to keep a number of different types of stillage. It would be advantageous to provide a more versatile stillage that can be used with a wide variety of goods.

A further problem associated with known stillages is that when subjected to wear individual components cannot be repaired in isolation and instead a whole new stillage must be provided.

The present invention seeks to mitigate the above-mentioned problems.

Alternatively or additionally, the present invention seeks to provide an improved stillage.

Summary of the Invention

In a first aspect of the invention there is provided a modular system for constructing a stillage, the system comprising a plurality of slats, and a plurality of beams, each beam having a first end, a second end, and one or more slat-recesses, and wherein, the first end of each beam is configured to form two interlocking joints at the same time, each joint being between the first end and an end of another beam, such that, in use, a plurality of beams can be interlocked to form the frame of a stillage, and each slat-recess is configured to receive a portion of a slat such that, in use, a slat can be mounted on and extend between at least two of said beams to form a side wall and/or deck of a stillage. Providing beams having an end that can connect to two other beams, and being configured to support a plurality of slats may facilitate the construction of a wide range of sfillages, for example stillages of different sizes and/or having different arrangements of side walls, posts and/or decks, thereby removing the need to store various different types of stillage. Stillages constructed using the modular system described above may also be broken down into their constituent elements thereby allowing for more compact storage and/or easier replacement of parts.

A stillage may comprise a deck, i.e. a surface upon which goods to be stored or transported can be placed. A stillage may comprise one or more side walls. Together the side walls and the deck may define, at least in part, a volume in which goods to be stored or transported may be received. Each side wall or deck may be constructed from one or more slats.

The deck and/or side walls may be supported on a frame. The frame may comprise a base which supports the deck. The frame may comprise one or more arms, each arm being connected at one end to the base and extending away from the base. The side walls may be supported on the arms. Each side wall may extend between at least two of the arms. The frame may comprise an upper rim. The rim may extend between the distal ends of the arms, at the opposite end of the arms to the base. Thus, the rim may increase the rigidity of the frame. Each element of the frame (e.g. the base, the arms, the rim) may be constructed from one or more beams.

Each beam of the frame may be joined to at least one other beam of the frame by an interlocking joint. An interlocking joint may be defined as a joint in which the elements to be joined comprise complementary portions shaped to interlock with one another. The complementary portions may for example be protrusions which fit into corresponding recesses. In an interlocking joint the elements to be joined may be shaped such that when joined together the relative movement of said elements is constrained in at least one degree of freedom.

Each slat may extend between at least two beams, for example two beams extending in parallel away from the base and/or two beams extending in parallel across the width of the base. Thus, the beams of the frame may support the slats that form a deck or side wall.

In use, the system may be used to construct a 'pallet'. In the pallet configuration the ends of a first set of beams may be interlocked, such that the first set of beams form a base. The first end of a beam of the first set may form a first interlocking joint with second end of a beam of the first set, e.g. with another beam forming the base of the stillage. The base may comprise four beams, the first end of each beam being interlocked with the second end of another beam to form a four-sided frame. The base may comprise more than four beams. In the pallet configuration, a first set of slats may be inserted in the slat-recesses of the beams of the first set to form a deck. The deck may be slatted, comprising slats spaced apart along the length of the beams. The deck may alternatively be solid, comprising slats located immediately adjacent to one another along the length of the beams.

In use, the system may be used to construct a 'stillage'. The stillage may comprise a first set of beams and a first set of slats arranged to form a pallet as described above.

The ends of each beam of a second set of beams may be interlocked to the ends of the beams of the first set such that each beam of the second set is substantially orthogonal to the deck. The beams of the second set may therefore form the arms of the stillage.

Each arm may comprise a single beam. The first end of a beam of the first set may form a second interlocking joint with an end, for example the second end, of a beam of the second set. The second set of beams (i.e. the arms) and the deck may define, at least in part, a volume in which goods to be transported or stored can be received. In the case that the first set comprises four beams, the second set may comprise four beams, and each beam of the second set may be connected at one of the four corners of the base.

However, it will be appreciated that a greater number of beams could be used in the second set.

In the stillage configuration one or more side walls may be constructed from the slats of the system. A second set of slats may be located in the recesses of the second set of beams such that each slat extends between at least two of said beams.

A side wall may be solid, for example a side wall may comprise slats located immediately adjacent to each other. A side wall may be slatted, comprising slats spaced apart along the length of the arms. A side wall may extend along the entire length of the arms. A side wall may extend along a partial length of the arms. The stillage may comprise more than one side wall. The side walls may extend around substantially the entire perimeter of the base. In the case that an arm is located at each corner of the base, the stillage may comprise four side walls.

The stillage may have any combination of slatted or solid walls and/or a slatted or solid deck.

In a further variation of the stillage, a third set of beams may be attached to the frame. Each beam of the third set of beams may be interlocked to the distal end of a beam of the second set of beams. Thus, in use, a first end of a beam of the third set may form a first interlocking joint with an end of a beam of the second set e.g. with the distal end of an arm. In use, a first end of a beam of the third set may form a second interlocking joint with the second end of another beam of the third set, e.g. with another beam in the rim of the frame. The beams of the third set may form a rim at the distal (upper) end of the frame. Each beam of the third set may be interlocked to another beam of the third set. The beams of the third set may be parallel but vertically separated from the beams of the base, so that an upper rim is formed on the frame, which matches the footprint of the base.

The first end of each beam may be substantially identical to the first end of any other beam. The second end of each beam may be substantially identical to the second end of any other beam. This may allow all the beams to interlock with any other beam in the same fashion. It will be appreciated that the plurality of beams may comprise beams of two or more different lengths each beam having the same shape and configuration at the first and second ends. Alternatively, each beam of the plurality of beams may be substantially identical to the other beams.

Each beam may comprise a plurality of slat-recesses formed in a face of the beam. The slat-recesses may be configured, for example sized and shaped, to receive a portion of a slat. It may be that, in use, a first portion of a slat is received in a slat-recess on a first arm (i.e. a first beam) and a second portion of a slat is received in a slat-recess on a second arm (i.e. a second beam). In this way, a plurality of slats may be used to form a side wall or deck between the two arms/beams. The slat may be retained in the beams by a friction fit with the recesses. In use, a slat forming part of a side-wall may be mounted so the longitudinal axis of the slat is parallel to the base and/or perpendicular to the longitudinal axis of the beam(s) supporting the slat.

The width and/or depth of each slat may be substantially identical to the width and/or depth of any other slat. This may allow all the slats to be received in the same shape of slat-recess. Each slat of the plurality of slats may be substantially identical to the other slats. Alternatively, the plurality of slats may comprise two or more different types of slats. For example, the plurality of slats may comprise slats of two or more, for example three, different lengths. The slats may have a non-planar cross-section, for example a ridged or corrugated cross-section. The slats may be substantially planar, having a flat upper and/or lower surface. The plurality of slats may comprise both corrugated slats and planar slats. The plurality of slats may comprise one or more slats having a cut-out, for example a chamfered corner.

The first end of each beam may be configured such that, in use, when two further beams are interlocked with said beam, the longitudinal axes of the two further beams are orthogonal to said beam, and to one another.

It may be that one end of each beam comprises at least one joint-recess and the other end of each beam comprises at least one joint-projection, each joint-recess being configured to receive a joint-projection, such that, in use, the interlocking joint comprises a joint-projection of a first beam received in a joint-recess of a second beam. Thus, each interlocking joint may comprise the joint-projection of one beam located in the joint-recess of a second, different, beam. Each first end of a beam may comprise two joint-projections or two joint-recesses, such that the first end can form an interlocking joint with an end of two other beams at the same time. It will be appreciated that in the case that a first end comprises two joint-recesses, each second end of a beam will comprise a joint-projection (and vice versa in the case that the first end comprises two joint-projections). A first joint-recess (or projection) may be located on a first side of the beam. A second joint-recess (or projection) may be located on a second side of the beam, said second side being substantially orthogonal to the first side. The corresponding joint-projection (or recess) may be located on a surface of the beam that is substantially orthogonal to each of the surfaces on which the first and second joint-recesses (or projections) are formed. For example, in the case that the two joint-recesses are located on two sides of the beam, the corresponding joint-projection may be located on an end surface of the beam (e.g. with the projection extending away from the end of the beam in a direction parallel to the longitudinal axis of the beam).

It may be that the modular system further comprises a plurality of locking pins, and each beam has at least one locking-recess at each end for accommodating a portion of a locking pin, each locking-recess being configured to align with a corresponding locking-recess of another beam when the two beams are part of the same interlocking joint, such that, when the interlocking joint is formed a locking pin may be placed in the aligned locking-recesses of the joined beams to limit movement of the beams with respect to one another. A locking-pin may provide a mechanically simple means of further constraining two beams relative to each other, and thereby increase the flexibility of the modular system.

Each beam may have a first locking-recess and a second locking-recess. Each beam may be configured such that the first and second locking-recesses align such that a locking pin can be received therein when an end of a first beam is located adjacent an end of a second beam (e.g. when the first and second beams are joined via an interlocking joint). Thus, the interlocking joint may further comprise a locking-pin received in a first locking-recess of the first beam and a second locking-recess of the second beam. Each beam may comprise a plurality of such locking-recesses, for example three locking-recesses at each end.

It will be appreciated that a joint-recess may function as a locking-recess depending on the orientation of the two beams in question. Thus, a joint-recess may be a joint-recess and a locking-recess.

A locking pin may be substantially cylindrical. Alternatively, the diameter of a locking pin may vary along its length. For example, a locking pin may have an hour glass shape. It will be appreciated that depending on the shape of the pin and the corresponding recess the pin may constrain relative movement of the two beams in two, or more than two, degrees of freedom.

It may be that each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially orthogonal to the surface in which the slat-recess is formed. Thus, a first type of slat-recess may be arranged such that the longitudinal axis of a slat received therein will extend in a direction substantially orthogonal to the face of the beam in which the recess is formed. That is to say, the first type of slat-recess may be configured to receive a slat end-on. Each slat-recess of the first type may be configured to receive a single slat, or a plurality of slats end-on. For example, the first type of slat-recess may comprise a groove running along a portion of the length of, for example the majority of the length of, the beam. Thus, each beam (or arm) may comprise a groove running along a portion of the length of the beam. It may be that, in use, a first end of a slat is located in the groove of a first beam (or arm), and the second end of the slat is located in the groove of a second beam (or arm).

It may be that each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially parallel to the surface in which the slat-recess is formed. A second type of slat-recess may be configured such that the longitudinal axis of a slat received therein will extend in a direction substantially parallel to the face of the beam in which the recess is formed. That is to say, the second type of slat-recess may be configured to receive a slat side-on. The depth of the second type of slat-recess may be such that when a slat is received therein, the front surface of the slat is substantially flush with the surface of the beam. The depth of the second type of slat-recess may be substantially the same as the thickness of the slat.

Each slat-recess of the second type may be configured to receive a plurality of slats side-by-side, or a single slat. For example, the beam (or arm) may comprise a plurality of the second type of slat-recess spaced apart along its length, each recess being configured to receive a single slat.

A first face of the beam may comprise one or more recesses of the first type and/or one or more recesses of the second type. For example, a first face of the beam may comprise both a groove running along the majority of the length of the first face and being configured to receive a plurality of slats end-on, and a plurality of spaced apart recesses, each configured to receive a single slat side-on. Having more than one type of slat-recess in a single face of the beam may increase the versatility of the modular system.

Alternatively, it may be that a beam has only one type of slat-recess, or that different faces of a beam have different types of slat-recess.

Each beam may comprise one or more slots, the or each slot being configured to receive one or more forks of a fork-lift truck. The slots may be configured such that the beam is maintained in a horizontal orientation when lifted by a fork-lift. Providing slots of this type may allow a stillage or pallet constructed from the system to be lifted by a fork-lift.

For example, when the beams are interlocked end-to-end to form a base, the slots may allow the base to be lifted by a fork lift truck. Each slot may extend throughout the thickness of the beam. It may be that each beam comprises two slots, each slot being sized to receive a fork of a fork-lift truck and configured such that, in use, the longitudinal axis of the beam is maintained in a horizontal orientation when the beam is lifted by a fork-lift using said slots.

The modular system may comprise a plurality of slot-inserts. Each slot-insert may be configured to fit in a slot such that an outer surface of the insert is substantially flush with the surface of the beam adjacent the slot. Each slot insert may cover the majority of the slot. In the case that the slot extends throughout the thickness of the beam, a pair of slot-inserts may be used. One of said pair may be positioned on each side of the beam. Each pair of slot-inserts may be joined together in a with a dowel, for example in a push-fit. Thus, the modular system may further comprise a plurality of dowels arranged to connect a pair of slot-inserts.

It may be that the outer surface of the slot-insert includes one or more slat-recesses. The outer surface may comprise one or more slot-recesses of the first or second type. Thus, in use, a slat, for example a slat forming part of a side wall or deck, may be received in the slat-recess of a slot-insert. That is to say, the beam may support the slat via the slot-insert. Providing slot-inserts may increase the configurability of the beams; the slots of the beams that form the base may be left unfilled, so the base can be lifted by a fork lift truck, the slots of the beams that are used elsewhere in the stillage may have an insert placed therein to provide slat-recesses on the sides that would otherwise be occupied by the slots. The pattern of slat-recess provided on the outer surface of the slot-insert may match the pattern of slat-recess provided on the face(s) of the beam. The slot insert may comprise one or more slat-recesses of the first type and/or one or more recesses of the second type described above. The slot insert may comprise two recesses of each type. In use, a slat-recess of the slot-insert may align with a slat-recess of the beam, for example where a beam comprises a groove running along its length, a similar groove may be provided on the slot-insert to continue said groove.

The modular system may further comprise one or more reinforcing struts. Each reinforcing strut may have a first end and a second end opposite the first end. Each end of a reinforcing strut may be configured to form an interlocking joint with a beam, for example the midpoint of a beam. Thus, in use, the reinforcing strut can strengthen the frame of the stillage. Each strut may extend between two beams, for example at a location midway between the ends of the beams. A middle portion of each beam may be configured to form an interlocking joint with an end of a reinforcing strut. For example, when the modular system is in the pallet configuration, a reinforcing beam may extend between two parallel beams in the base to strengthen the resulting pallet. The strut may be wedged within the frame being removable only when the frame-members are disassembled.

Each reinforcing strut may comprise one or more slots configured to receive one or both forks of a fork-lift truck. The reinforcing strut may be configured such that in use, the or each slot of the strut aligns with the or each slot of a beam. The strut may comprise a diamond (or other) shaped dowel for resisting wear from repeated lifting by fork-lift arms. The inclusion of the dowel may serve to prolong the life of the stillage. The dowel may be located in a central bridging portion of the strut.

The strut may comprise one or more recesses of the first type and/or one or more recesses of the second type described above. In use, the recesses may align with corresponding recesses in the beams of the frame. Such an arrangement may enable the reinforcing strut to provide additional support to slats which are mounted on opposing beams thereby strengthening the deck or sidewall further.

Each beam may have a length very much greater than its width and/or depth. Each beam may be substantially cuboidal, for example each beam may comprise a substantially rectangular member. Each beam may have six faces; four side faces and two end faces. The slat-recesses may be formed in the side faces of the beam.

Two of the four side faces, located on opposite sides of the beam, may comprise slat-recesses of the first and/or second type. The slots Of present) may extend between the other two of the side faces. When slot-inserts are inserted in the slots, slat-recesses of the first and/or second type may be provided in the other two side faces so that the beam has slat-recesses on all four side faces. Alternatively, the other two of said side faces may comprise slat-recesses of the first and/or second type.

It may be that the beams and/or slats are made of plastic, for example polyethylene. It will be appreciated that a number of other materials could be used including wood. The beams and slats may be exclusively made of medium density polyethylene, for example aerated medium density polyethylene. The beams and slats may be predominantly made of medium-density polyethylene, for example aerated medium density polyethylene.

In a second aspect of the invention, there is provided a method of building up a sfillage using a modular system comprising a plurality of slats and a plurality of beams, each beam having a first end and a second end, each first end being configured to form two interlocking joints at the same time, and wherein each beam comprises at least one slat-recess configured to receive a portion of a slat, the method comprising the following steps: interlocking the first end of each beam of a first set of beams with the second end of a beam of the first set to form a base, and then - inserting a plurality of slats into the at least one slat-recess of the beams of the first set to form a deck on the base, and interlocking an end of each beam of a second set with the first end of a beam of the first set, such that each beam of the second set extends away from the deck, the second set of beams and the deck thereby defining, at least in part, a volume in which goods can be 35 received.

The step of interlocking the first set of beams to form a base may comprise interlocking a first end of a first beam to a second end of a second beam, such that the first beam and second beam are substantially perpendicular. The first set may comprise four beams. Each beam may be substantially orthogonal to the two adjacent beams.

Thus, the base may comprise four beams with the interlocking joints located one at each of the four corners of the base.

The step of inserting the slats to form a deck on the base may comprise inserting each slat into two slat-recesses, one slat-recess being located on each of two parallel beams that make up the base. Thus, the slats of the deck may extend between two parallel beams.

The step of forming the deck may comprise providing a further layer of slats located on top of the slats inserted into the slat-recesses of the base (the first layer). The longitudinal axes of the slats of the further layer may extend between two beams of the base in a direction perpendicular to the longitudinal axes of the slats of the first layer.

Providing two layers of slats oriented perpendicularly to one another may increase the strength of the deck of the stillage thereby increasing the range of stillages that can be constructed from the modular system by allowing for the transport of heavier goods. The slats of the deck may extend only part way across the top surface of each beam of the base. Such an arrangement may enable the base beams to support not only the slats of the deck, but also slats of a side wall at the same surface.

The slats of the first and/or the further layer may be immediately adjacent to each other or spaced apart from each other, depending on the slat-recesses into which they are inserted. For example where multiple slats are inserted into the same slat-recesses the slats of the resulting deck (or side wall) may be immediately adjacent to each other. In the case that each slat is inserted into a different slat-recess the spacing between said slat-recesses will determine the gaps between the slats in the resulting deck (or side wall).

It may be that the method further comprises the step of inserting a portion of each slat of a second set of slats into the recesses of two or more of the beams of the second set, to define one or more side walls of the stillage.

The side wall may be a solid side wall. The method may comprise forming a solid side wall by inserting a plurality of slats into the same slat-recess. For example, the method may comprise inserting a plurality of slats into a slat-recess of the first type, for example a groove extending along the length of a beam. Thus, a solid wall may be formed between two beams, the beams having a slat-recess of the first type extending along opposing faces.

The side wall may be a slatted side wall. The method may comprise forming a slatted side wall by inserting a different slat into each one of a plurality of slat-recesses spaced apart along the length of a beam. For example, the method may comprise inserting different slats into each of a plurality of slat-recesses of the second type. Thus, a slatted side wall may be formed between two beams, the beams having spaced apart slat-recesses of the second type extending along faces that face in the same direction. The slat-recesses may be evenly spaced, and located at the same heights on each of the beams so that slats inserted in the slat-recesses may be substantially parallel to the deck.

It may be that the method further comprises the step of interlocking an end of each beam of a third set with another beam of the third set and the distal end of a beam of the second set to define a rim of the stillage.

It may be that each beam comprises two slots, each slot being sized to receive at least one fork of a fork-lift truck, and wherein the method comprises inserting a slot-insert into said slot such that the outer surface of said slot-insert is substantially flush with the surface of the beam in the region of the slot. The slot may be substantially covered by one or more slot-inserts.

The method may further comprise the step of connecting a reinforcing strut between two of the beams making up the frame of the stillage. For example, the method may comprise connecting a reinforcing strut between two of the beams making up the base of the stillage.

It may be that the method further comprises breaking down the stillage by removing the slats from the slat-recesses and detaching the beams from each other.

In a third aspect of the invention, there is provided a stillage comprising a base and at least two arms, each arm being connected to the base at a first end and extending away from the base, and a plurality of slats, each slat extending between at least two arms to define, at least in part, a side wall of the stillage, and wherein each arm comprises one or more slat-recesses in which a portion of a slat is received such that the side wall may be broken down and built up by removing the slats from and inserting the slats into said one or more recesses. Providing side walls that can be broken down and built back up may increase the versatility of the stillage.

Each arm may comprise slat-recesses in a first face and a second face, the second face being substantially perpendicular to the first face. Thus, each arm may support one end of two side walls, the two side walls extending perpendicular to each other. The stillage may comprise four arms, one at each corner of the base. The stillage may comprise four side walls, one between each pair of arms.

It may be that the base comprises one or more slat-recesses in which a portion of a slat is received when said slat is extending between said at least two arms. Thus, a portion of the lower most slat (i.e. the slat closest to the base) may be received in a recess in the base. Providing such a recess in the base may strengthen the side wall and facilitate alignment of the slats. It will be appreciated that the base may be constructed using the modular system of the present invention and accordingly, the slat-recess of the base may comprise a slat-recess formed in a beam.

It may be that a slat extends between two arms, each of said two arms having a first face which opposes the first face of the other of said arms, each first face comprising a recess in which a portion of the slat is received such that the longitudinal axis of the slat is substantially perpendicular to the first face.

It may be that a slat extends between two arms, each arm having a second face, both second faces facing in the same direction and comprising a recess in which a portion of the slat is received such that the longitudinal axis of the slat is substantially parallel to the second faces.

In a fourth aspect of the invention, there is provided a method of constructing a stillage, the stillage comprising a base and at least two arms, each arm being connected to the base at a first end and extending away from the base, and comprising one or more slat-recesses configured to receive a portion of a slat, the method including the steps of building up a side wall between two arms by inserting the ends of a plurality of slats into the slat-recesses of the two arms. The method may comprise the step of breaking down a side wall be removing the ends of the plurality of slats from the slat-recesses of the two arms.

In a fifth aspect of the invention there is provided a stillage comprising a base, and one or more arms, each arm being connected to the base at a first end by an interlocking joint, the joint being configured such that the step of mounting each arm on the base comprises moving each arm relative to the base in a direction parallel to the plane of the base to bring a portion of the arm into interlocking engagement with a portion of the base.

Configuring the interlocking joint in this way may enable the arms to be mounted on or removed from the base independently of one another and/or while goods are resting on the base.

The base may be constructed using the modular system described above. The base may comprise the modular system arranged in the pallet configuration.

It may be that the first end of each arm comprises a projection, and the base comprises a corresponding slot, and the method comprises inserting the projection into the slot and then moving the arm relative to the base to bring the projection into interlocking engagement with the slot.

It may be that each arm comprises a first locking-recess and the base comprises a corresponding second-locking recess, and wherein the step of mounting the arm on the base brings the first locking-recess into alignment with the second locking-recess, and the method comprises inserting a locking pin into the first and second locking recesses when they are so aligned.

In a sixth aspect of the invention there is provided a method for constructing a stillage, the stillage comprising a base and one or more arms, wherein the step of connecting each arm to the base comprises bringing a portion of the arm into interlocking engagement with the base by moving the arm relative to the base in a direction parallel to the plane of the base.

In further aspects of the invention, there are provided a beam, slat, reinforcing strut and/or locking pin suitable for use as the beam, slat, reinforcing strut and/or locking pin of any other aspect.

In a still further aspect of the invention, there is provided a pallet or stillage constructed using the modular system of the first aspect. Such a pallet or stillage may comprise the modular system arranged in any of the 'pallet' or 'stillage' configurations described above. It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, features described with reference to the 'beam' of the first (or any other) aspect, may equally apply to the 'arm' of any other aspect, and vice versa. Similarly, features described with reference to the method of the present invention may equally apply to the apparatus, and vice versa. The method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa.

Description of the Drawings

Example embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings of which: Figures 1 (a) and (b) are perspective views of a beam for use in a modular system according to a first example embodiment of the invention; Figure 2 is a perspective view of a reinforcing strut for use in the modular system of the first embodiment; Figure 3 is a perspective view of a slat for use in the modular system of the first embodiment; Figure 4 is a perspective view of a pallet constructed using the modular system of the first embodiment; Figure 5 is a perspective view of a stillage constructed using a modular system according to a second example embodiment; Figure 6 is a perspective view of the elements of a modular system in accordance with a third example embodiment; Figure 7 is a perspective view of a base of a stillage constructed using the system of the third embodiment; Figure 8 is a perspective view of a base of a stillage constructed using the system of the third embodiment; and Figure 9 is a perspective view of a stillage constructed using the system of the third embodiment.

Detailed Description

Figs. 1(a) and 1(b) show two views of a beam 3 of a modular system according to a first embodiment of the invention. The beam 3 comprises an elongate rectangular member which has a roughly rectangular cuboidal form having four sides; top 18, bottom 22, left-hand 20, and right-hand 26 sides (in the orientation shown in Figure 1(a)) and two end surfaces 24, 28. The beam 3 has a first end portion 25 adjacent the end surface 24, and a second end portion 27 adjacent the end surface 28.

The beam 3 has a groove 37 running along the centre line of each of its top 18 and bottom 22 surfaces. Each of the top 18 and bottom 22 surfaces also includes four cut-out regions 9 which are approximately square when viewed in plan, and spaced apart along the length of the beam 3. The groove 37 bisects the cut-out regions 9. Each cut-out region 9 has a corrugated shape to receive a corrugated slat 11 (see Fig. 3).

The first end-portion 25 (see Fig. la) has a channel 33, extending from the end of the beam inwards along the top surface 18. Similar channels are located on the left-hand side 20, bottom 22 and end 24 surfaces of the beam in the region of the first end-portion 35 25.

The second end portion 27 (see Fig. lb) has a head 31 protruding longitudinally from the end surface 28 of the beam 3. Channels 33, also extend from the end of the beam inwards along the top surface 18 and bottom surface 22 in the region of the second end-portion 27.

Each end-portion 25, 27 also has small recesses 35, each sized and shaped to receive one half of a pin 17 (see Fig. 4). The first end 25 has two small recesses 35, one extending downwards along the left-hand surface 20 from the top edge, and one extending upwards along the left-hand surface 20 from the bottom edge. The second end 27, has two small recesses 35, both in the end surface 28, one extending upwards from the bottom edge and the other extending downwards from the top edge and overlapping with the ends of the channels 33.

Away from the end portions 25, 27, two holes 29 for fork-lift truck arms extend through the beam 3 between the left-hand 20 and right-hand 26 sides. Bracing wall 23 extends across the beam 3 at the midpoint of the beam 3, between the two holes 29.

The edges of bracing wall 23 are crenelated.

In use, the protruding head 31 of a beam 3 can be inserted in any of the channels 33 in either the first 25 or second 27 end-portions of another beam 3. The head 31 can be slid along the channel 33 to bring the two beams 3 into interlocking engagement. Thus, a head 31 and a channel 33 may form part of an interlocking joint. At the first end portion 25, the multiple orthogonal channels 33 mean that two (or more) heads 31, and therefore two or more beams, can be interlocked in this manner. For example, beams can be connected to the top 18, bottom 22 and left-hand 20 sides simultaneously. Accordingly, a modular system having beams in accordance with the present embodiment can be used to produce a variety of different frames for use in constructing a stillage.

In order to prevent the head 31 falling out of the channel 33 while the system is in use, a locking pin 17 (see Fig. 6) may be used to further constrain relative movement of the two beams 3 in the region of the joint. For example, when two beams are interlocked via a head 31 received in the channel 33 of left-hand side 20 as described above, the channel 33 in the top surface 20 of the second end portion 27 of one beam 3 will be aligned with the small recesses 35 in the left hand surface 20 of the first end portion 25 of the other beam, and a pin 17 can be inserted into the resulting larger recess. The pin 17 thereby prevents movement of the two beams that would result in the head 31 moving along the channel 33. In some orientations a channel 33 will align with a small recess 35, in other orientations two small recesses 35 align with each other to form a recess in which a pin 17 can be received.

Fig. 2 shows a close-up view of a supporting strut 7, for use in a modular system in accordance with the first embodiment of the invention. The strut 7 (as shown in Fig. 2) has a top surface 41, a left-hand surface 42, a lower surface 43, a right-hand surface 44 and two end portions 47, 49. The strut 7 has teeth 53 protruding from each end and corresponding to the crenelations of the bracing wall 23 of each beam 3. Similar to the beam 3, the strut 7 has two holes 51 sized and shaped to accommodate fork-lift arms along its length. Adjacent the edge of the holes 51 is a diamond shaped dowel 45 which provides additional strength to the strut 7.

The strut 7 has cut-out regions 13, sized and shaped to accommodate slats 11.

The top surface 41 and bottom surface 42 each have four spaced apart cut-out regions 13 which extend across the strut, perpendicular to the longitudinal axis of the strut 7. Each cut-out region 13 has a corrugated shape to receive a corrugated slat 11.

In use, a strut 7 may extend between the bracing walls 23 of two parallel beams 3 to increase the rigidity of a frame constructed from said beams.

Fig. 3 shows a close-up view of a slat 11 for use in a modular system in accordance with the first example embodiment. The slat 3 comprises an elongate member having a width and length very much greater than its thickness. The slat 3 is corrugated, the longitudinal axis of each ridge being substantially parallel to the longitudinal axis of the slat.

Fig. 4 shows a pallet 1 constructed using a modular system according to the first example embodiment. The pallet 1 has a square base 2, each side of the base 2 being formed by a beam 3. Each beam 3 is connected to another beam 3 by an interlocking joint at a corner of the base 2. A supporting strut 7 extends across the base 2 between an opposing pair of the beams 3. The ends of slats 11 are received in the cut-out portions 9 on the top 18 and bottom 22 surfaces of the beams 3 (as orientated in Fig. 4 left-hand surface 20 of each beam 3 faces inwards towards the centre of the pallet 1, and right-hand surface 26 faces outwards). The slats 11 extend between an opposing pair of beams 3, perpendicular to the central supporting strut 7 to form an upper deck 4 and a lower deck 6 on the base 2. A centre portion of each slat 11 is received in a cut-out region 13 on the top 41 or bottom 43 surface of the strut. The pallet 1 has four slats 11 extending across the base 2 on each of its upper and lower sides. The slats 11 are evenly spaced across the pallet 1. The slats are corrugated, providing a textured upper/lower surface to the structure. Filler pieces 15 are inserted in the cut-away portions 9 of the beams 3 that are not occupied by slats 11.

Each beam 3 is connected to two other beams 3, one at each end via an interlocking joint. The join between adjacent beams 3 of the base 2 is formed by the protrusion 31 of one beam being received in a channel 33 of the other beam. For example, at the bottom right-hand corner of the pallet (labelled A in Figure 1), the head 31 of a first beam 3a has been inserted into a channel on the inward facing surface 20 of a first end 25 of a second beam 3b. The beams 3a and 3b are therefore orthogonal to each other. A small recess 35 in the first end 25 of beam 3b is aligned with a channel 33 in the top surface 18 of the second end 27 of beam 3a and a pin 17 is located in the aligned recesses. This pattern is repeated at each corner of the base of Fig. 1.

The pallet of Fig. 1 is constructed by interlocking the ends of four beams 3 to form a base 2, and then inserting the slats 11 into the recesses 9 of the top 18 and bottom 22 surfaces of the beams 3 of the base 2 where they are retained by means of a friction fit to form a deck 4, 6. The interlocking joint is formed by the movement of one frame-member 3a relative to the other 3b in a direction parallel to the plane of the base 2 so that the head 31 moves along the channel 33, away from the end surface 24 of the first end 25. Since beams 3 join by sliding, the pallet can be easily dismantled by sliding the beams 3 in the opposite direction. Accordingly, pallets constructed using the modular system of the present invention may be easier to break down and build up compared to those produced using other prior art systems.

By extending between the small recess 35 of one beam 3a and a channel 33 of the other beam 3h, locking pin 17 acts to prevent accidental disconnection by constraining the movement of the two adjacent beams 3a, 3b in a direction perpendicular to the longitudinal axis of the pin 17-a direction that would result in the head 31 sliding out of the channel 33 (i.e. moving along channel 33 towards the end surface 24).

During construction of the base 2, the strut 7 is positioned between a parallel pair of beams 3. The teeth 53 of the strut 7 grip onto the crenellafions of the bracing walls 23, of the adjacent beams 3. Thus, when the base 2 is constructed, the strut 7 is wedged between the two beams 3, and cannot be removed without dismantling the base 2. The strut 7 gives the base 2 additional rigidity. However, it will be appreciated that the presence of a strut 7 is not always necessary, depending on the characteristics of the goods in question and accordingly this is an optional feature of the modular system.

The holes 29 in the beams 3 of the base 2 allow the pallet 1 to be lifted by a fork-lift truck. Pallets in accordance with the present invention can thus be lifted by fork-lift approaching from any of their four sides.

In an alternative configuration (not shown), the deck of the pallet may have slats running transversely rather than longitudinally across the frame. In that arrangement, the slats would not pass through the central supporting beam, but rather would pass either side of it.

Figure 5 shows a stillage 55 formed using a modular system in accordance with a second example embodiment of the invention. Only those elements of the second embodiment which differ with respect to the first embodiment will be discussed here. Like reference numerals denote like elements. In contrast to the modular system of the first embodiment, the modular system of the second embodiment includes insert panels 59 which are configured to cover the fork-lift holes 29 in a beam 3. The inserts 59 have a surface profile which includes cut-out regions 9' and grooves 37' to provide a surface profile similar to that of the surfaces 18, 22 of the beam 3 (as shown in Figure 1(a)). Each beam 3 has two inserts 59 located in each fork-lift hole 29. The inserts 59 on opposing sides of the beam 3 join together with dowels 52 (see Fig. 6) which fit into recesses 54 on the inner sides of opposing inserts 59.

The inserts 59 are fitted to the arm 57 to cover the fork-lift holes 29 in the arm 57 (i.e. either side of the bracing wall 23). The inserts 59 thereby close over the open sides 20, 26 of the beam 3 producing a pillar-like arm 57.

The base 61 of the stillage 55 is essentially the same as the pallet 1 of Figure 1, but without the lower deck 6 or fillers 15. The stillage 55 has four arms 57, each arm extending vertically away from each corner of the base 61. Each arm 57 comprises a single beam 3 of the modular system. Each beam 3 forming an arm 57 is connected at one end to the first end portion 25 of a beam 3 of the base 61 The resulting arm 57 is orthogonal to the beam 3 of the base 61.

On two sides slats 11 extend horizontally between the arms 57, to form side walls (in some configurations side walls 60 may be formed on all four sides). At one end, the slats 11 are located in the cut-out portions 9 of the surface 20 of the beam 3, this surface 20 faces outward and extends perpendicular to the base 61 when a beam 3 is acting as an arm 57. At the other end of the slats 11, an insert panel 59 is located in the holes 29 for the fork-lift arms. The other end of the slats 11 are received in the cut-out regions 9' in the outer surface of insert 59.

In use, to form the stillage 55, the arms 57/beams 3 attach to the base 61 by sliding in a direction parallel to the plane of the base 61. The slide lock formed is substantially the same as the slide lock formed between beams 3 of the base. The head 31 on the second end 25 of the arm 57/beam 3 is received in the channel 33 on the top surface 18 at the first end 27 of beam 3a. A small recess 35 in the end surface 28 of the arm 57/beam 3 aligns with a channel 33 in the end surface 24 of the first end 27 of the beam 3a to form a recess in which an interlocking pin 17 is inserted to constrain the arm 57. In this configuration, the cut-out regions 9, 9' accommodate slats 11 which extend around the outside of the arms 57 to form the walls of the stillage 55. Each slat 11 is slid into cut-out 9, 9' in the outwardly facing surface of an arm 57 and extends horizontally across the side of the stillage 55. Each slat 11 is held to the frame by a friction fit in the cut-out 9, 9', with its longitudinal axis parallel to the face of the arm in which the slat-recess is formed. Additional slats 11 are fixed to the arms 57 in a similar manner. Thus side walls 60 are built up around the pallet, the slats 11 being spaced apart by a distance corresponding to the vertical separation of the cut-outs 9, 9' in the arms 57.

Fig. 6 shows the elements of a modular system in accordance with a third example embodiment of the invention. Only those elements of the third embodiment that differ with respect to the second embodiment will be discussed. Like references denote like elements. In contrast to the modular system of the second embodiment, the modular system of the third example embodiment includes slats 11 of different lengths. Slats 11 a are the same length as the slats of the first example embodiment (long slats), slats llb (short slats) are shorter than slats 11a. Slats 11c (medium slats) have a length in-between that of slats 11 a and 11 b. The modular system of the second example embodiment also includes slats 11 b' (see Fig. 8), having the same length as slats 11 b but with a cut out 81 at one corner. In the third embodiment, the dowels 52 connecting insert panels 59 have the same form as locking pins 17, thereby reducing the number of different elements in the system. Three recesses 54 are formed on the inside of each panel 59 and receive the dowels 52 when the system is assembled.

Figures 7 to 9 show a stillage 63, formed using a modular system in accordance with the third example embodiment. Only those elements of the stillage 63 which differ with respect to the stillage of Figure 4 will be discussed.

Fig. 7 shows the base 71 of the stillage 63. In the base 71 shorter slats 11 b extend between beams 3 and perpendicular to strut 7 to provide a first layer 73 of a deck.

In contrast to the stillage 55 where the longer slats 11 a which extend to the outside edge of the base 2 when used in the pallet configuration, the shorter slats llb only extend part way across the top surface 18 of the beam 3 to the inward edge of the groove 37. Using the shorter slats llb therefore leaves the grooves 37 free to receive a portion of a slat 11 when said slat 11 is forming a side wall between two arms 57.

Fig. 8 shows the base 71 of the stillage 63 with a second 79 layer of slats 11 b on top of the first layer of slats 73. The second layer 79 of slats llb rests freely on top of the first layer 73, oriented perpendicularly to the first layer 73. However, unlike the first layer 73, the second layer 79 has slats positioned side-by-side. At each end of the second layer 79, two edge slats 11 b' have cut-away segments 81 at the corners of the base 71, to allow space for the arms 57 to attach.

As shown in Fig. 9, the side walls 70 of the stillage 63 are formed from medium length slats 11c, the ends of which are located in the grooves 37 running along the length of the arms 57/beams 3. Thus, in contrast to the Fig. 5 configuration, the slats in the present configuration extend between the opposing faces of two arms 57, rather than the outside faces. As the slats 11c are inserted into continuous grooves 37 the slats 11c lie immediately adjacent to each other to form a solid wall 70. The bottom edge of the bottom slat 11c of each wall is retained in the groove 37 in the top surface 18 of a beam 3 making up the base 71. Fig. 9 shows the stillage 63 with three side walls, however it will be appreciated that four side walls may be constructed to form a crate.

The stillage 63 has an upper rim 69 formed of four beams 3, each beam 3 of the rim 69 connected to the upper end of an arm 57. The upper rim 69 may strengthen the stillage 63 as compared to, for example, the stillage 55.

In use, the insert panels 59 are attached to the arms 57 using dowels 52. A panel 59 is placed on one side of the beam 3 and three connecting dowels 52 are fitted in the three recesses 54 on the inner surface of the panel 59. A second panel 59 is then fitted on the opposing side of the beam 3, the connecting dowels 52 fitting into the recesses 54 of the second panel 59, so that the two panels 59 are held together across the beam 3. This is repeated for each fork-lift hole 29 in the beams 3 that form the arms 57.

An upper rim 69 is added to the stillage 63 by connecting four beams 3, a second end 27 of each beam being connected to a first end 25 of another beam in the rim 69. A first end 25 of each beam 3 making up the arms 57 is then connected to a first end 25 of a beam 3 in the rim 69. Thus, in the rim 69 the first ends 25 of two beams 3 are connected together. This is achieved by using a locking pin 17 in the channel 33 of the surface 20 of the arm beam 3 and the small recess 35 in the bottom surface 22 of the first end 25 of the rim beam 3. Whilst the present invention has been described and illustrated with reference to a particular embodiment, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.

While the embodiments above describe the interlocking joint being formed by sliding a projection in a channel, it will be appreciated that other types of form interlock may be used. For example, the stillage may have an interlocking joint formed by pushing rather than sliding protrusions into respective recesses, and/or using resilient portions.

The interlocking joint may not use locking pins.

It will also be appreciated that a wide variety of sfillages may be produced using the modular system of the present invention. For example, an alternative stillage may comprise more than four arms, or fewer than four arms and/or may comprise more than four beams in the base or fewer than four beams in the base.

Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.

Aspects and embodiments of the invention are summarised by way of the following numbered clauses: 1 A modular system for constructing a stillage, the system comprising: a plurality of slats, and a plurality of beams, each beam having a first end, a second end, and one or more slat-recesses, and wherein, the first end of each beam is configured to form two interlocking joints at the same time, each joint being between the first end and an end of another beam, such that, in use, a plurality of beams can be interlocked to form the frame of a stillage, and each slat-recess is configured to receive a portion of a slat such that, in use, a slat can be mounted on and extend between at least two of said beams to form a side wall and/or deck of a stillage.

2 A modular system according to clause 1, wherein one end of each beam comprises at least one joint-recess and the other end of each beam comprises at least one joint-projection, each joint-recess being configured to receive a joint-projection, such that, in use, the interlocking joint comprises a joint-projection of a first beam received in a joint-recess of a second beam.

A modular system according to clause 1 or clause 2, wherein the modular system further comprises a plurality of locking pins, and each beam has at least one locking-recess at each end for accommodating a portion of a locking pin, each locking-recess being configured to align with a corresponding locking-recess of another beam when the two beams are part of the same interlocking joint, such that, when the interlocking joint is formed a locking pin may be placed in the aligned locking-recesses of the joined beams to limit movement of the beams with respect to one another.

A modular system according to any previous clause, wherein each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially orthogonal to the surface in which the slat-recess is formed.

A modular system according to any previous clause, wherein each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially parallel to the surface in which the slat-recess is formed.

A modular system according to any previous clause, wherein each beam comprises two slots, each slot being sized to receive a fork of a fork-lift truck and configured such that, in use, the longitudinal axis of the beam is maintained in a horizontal orientation when the beam is lifted by a fork-lift using said slots.

A modular system according to any previous clause, the system further comprising a plurality of slot-inserts, each slot-insert being configured to fit in a slot such that an outer surface of the slot-insert is substantially flush with the surface of the beam adjacent the slot. 4 5 6 7 8. 9. 10. 11. 13. 14. 15.

A modular system according to any previous clause, wherein the outer surface of the slot-insert includes one or more slat-recesses.

A modular system according to any previous clause, wherein the beams and slats are made of plastic.

A beam suitable for use as the beam of any previous clause.

A slat suitable for use as the slat of any previous clause.

A method of building up a stillage using a modular system comprising a plurality of slats and a plurality of beams, each beam having a first end and a second end, each first end being configured to form two interlocking joints at the same time, and wherein each beam comprises at least one slat-recess configured to receive a portion of a slat, the method comprising the following steps: interlocking the first end of each beam of a first set of beams with the second end of a beam of the first set to form a base, and then inserting a plurality of slats into the at least one slat-recess of the beams of the first set to form a deck on the base, and interlocking an end of each beam of a second set with the first end of a beam of the first set, such that each beam of the second set extends away from the deck, the second set of beams and the deck thereby defining, at least in part, a volume in which goods can be received.

A method according to clause 12, further comprising the step of inserting a portion of each slat of a second set of slats into the recesses of two or more of the beams of the second set, to define one or more side walls of the stillage.

A method according to clause 12 or 13, further comprising the step of interlocking an end of each beam of a third set with another beam of the third set and the distal end of a beam of the second set, to define a rim of the stillage.

A method according to any of clauses 12 to 14, wherein each beam comprises two slots, each slot being sized to receive at least one fork of a fork-lift truck, and wherein the method comprises inserting a slot-insert into said slot such that the outer surface of said slot-insert is substantially flush with the surface of the beam in the region of the slot.

16 A method according to any of clauses 12 to 15, further comprising breaking down the stillage by removing the slats from the slat-recesses and detaching the beams from each other.

17 A stillage comprising a base and at least two arms, each arm being connected to the base at a first end and extending away from the base, and a plurality of slats, each slat extending between at least two arms to define, at least in part, a side wall of the stillage, and wherein each arm comprises one or more slat-recesses in which a portion of a slat is received such that the side wall may be broken down and built up by removing the slats from and inserting the slats into said one or more recesses.

18. A stillage according to clause 17, wherein the base comprises one or more slat-recesses in which a portion of a slat is received when said slat is extending between said at least two arms.

19 A stillage according to clause 17 or clause 18, wherein a slat extends between two arms, each of said two arms having a first face which opposes the first face of the other of said arms, each first face comprising a recess in which a portion of the slat is received such that the longitudinal axis of the slat is substantially perpendicular to the first face.

20 A stillage according to any of clauses 17 to 19, wherein a slat extends between two arms, each arm having a second face, both second faces facing in the same direction and comprising a recess in which a portion of the slat is received such that the longitudinal axis of the slat is substantially parallel to the second faces.

21 A stillage comprising a base, and one or more arms, each arm being connected to the base at a first end by an interlocking joint, the joint being configured such that the step of mounting each arm on the base comprises moving each arm relative to the base in a direction parallel to the plane of the base to bring a portion of the arm into interlocking engagement with a portion of the base.

22 A stillage according to clause 21, wherein the first end of each arm comprises a projection, and the base comprises a corresponding slot, and the method comprises inserting the projection into the slot and then moving the arm relative to the base to bring the projection into interlocking engagement with the slot.

23 A sfillage according to clause 22, wherein each arm comprises a first locking-recess and the base comprises a corresponding second-locking recess, and wherein the step of mounting the arm on the base brings the first locking-recess into alignment with the second locking-recess, and the method comprises inserting a locking pin into the first and second locking recesses when they are so aligned.

Claims

CLAIMS1 A modular system for constructing a pallet, the system comprising: a plurality of slats, and a plurality of beams, each beam having a first end, a second end, and one or more slat-recesses; and wherein, the first end of each beam is configured to form an interlocking joint with the second end of another beam, such that, in use, a plurality of beams can be interlocked to form the frame of a pallet, and each slat-recess is configured to receive a portion of a slat such that, in use, a slat can be mounted on and extend between at least two of said beams to form a deck of a pallet.
2 A modular system according to claim 1, wherein one end of each beam comprises at least one joint-recess and the other end of each beam comprises at least one joint-projection, each joint-recess being configured to receive a joint-projection, such that, in use, the interlocking joint comprises a joint-projection of a first beam received in a joint-recess of a second beam.
3 A modular system according to claim 1 or claim 2, wherein the modular system further comprises a plurality of locking pins, and each beam has at least one locking-recess at each end for accommodating a portion of a locking pin, each locking-recess being configured to align with a corresponding locking-recess of another beam when the two beams are part of the same interlocking joint, such that, when the interlocking joint is formed a locking pin may be placed in the aligned locking-recesses of the joined beams to limit movement of the beams with respect to one another.
4 A modular system according to any previous claim, wherein each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially orthogonal to the surface in which the slat-recess is formed.
A modular system according to any previous claim, wherein each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially parallel to the surface in which the slat-recess is formed. 8. 9. 10. 11.
A modular system according to any previous claim, wherein each beam comprises two slots, each slot being sized to receive a fork of a fork-lift truck and configured such that, in use, the longitudinal axis of the beam is maintained in a horizontal orientation when the beam is lifted by a fork-lift using said slots.
A modular system according to any previous claim, the system further comprising a plurality of slot-inserts, each slot-insert being configured to fit in a slot such that an outer surface of the slot-insert is substantially flush with the surface of the beam adjacent the slot.
A modular system according to any previous claim, wherein the outer surface of the slot-insert includes one or more slat-recesses.
A modular system according to any previous claim, wherein the beams and slats are made of plastic.
A beam suitable for use as the beam of any previous claim.
A slat suitable for use as the slat of any previous claim.
A method of building up a pallet using a modular system comprising a plurality of slats and a plurality of beams, each beam having a first end and a second end, each first end being configured to form a first interlocking joint with a second end of another beam, and wherein each beam comprises at least one slat-recess configured to receive a portion of a slat, the method comprising the following steps: interlocking the first end of each beam of a first set of beams with the second end of another beam of the first set to form a base, and then -inserting a plurality of slats into the at least one slat-recess of the beams of the first set to form a deck on the base, and wherein the deck thereby defines a surface on which goods can be placed.
13. A method according to claim 12, wherein each beam comprises two slots, each slot being sized to receive at least one fork of a fork-lift truck, and wherein the method comprises inserting a slot-insert into said slot such that the outer surface of said slot-insert is substantially flush with the surface of the beam in the region of the slot.
14 A method according to claim 12 or claim 13, further comprising breaking down the stillage by removing the slats from the slat-recesses and detaching the beams from each other.
A pallet comprising a base and a plurality of slats, the base comprising: a plurality of beams, each beam having a first end, a second end and one or more slat-recesses; and wherein, the first end of each beam is configured to form an interlocking joint with the second end of another beam, such that, in use, a plurality of beams can be interlocked to form the base of the pallet, and each slat-recess is configured to receive a portion of a slat such that, in use, a slat can be mounted on and extend between at least two of said beams to form a deck of the pallet.
16 A pallet according to claim 15, wherein one end of each beam comprises at least one joint-recess and the other end of each beam comprises at least one joint-projection, each joint-recess being configured to receive a joint-projection, such that, in use, the interlocking joint comprises a joint-projection of a first beam received in a joint-recess of a second beam.
17 A pallet according to claim 15 or claim 16, further comprising a plurality of locking pins, and each beam has at least one locking-recess at each end for accommodating a portion of a locking pin, each locking-recess being configured to align with a corresponding locking-recess of another beam when the two beams are part of the same interlocking joint, such that, when the interlocking joint is formed a locking pin may be placed in the aligned locking-recesses of the joined beams to limit movement of the beams with respect to one another.
18. A pallet according to any of claims 15 to 17, each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially orthogonal to the surface in which the slat-recess is formed.
19 A pallet according to any of claims 15 to 18, wherein each beam comprises one or more slat-recesses configured such that the longitudinal axis of a slat received therein will extend in a direction substantially parallel to the surface in which the slat-recess is formed.
A pallet according to any of claims 15 to 19, wherein each beam comprises two slots, each slot being sized to receive a fork of a fork-lift truck and configured such that, in use, the longitudinal axis of the beam is maintained in a horizontal orientation when the beam is lifted by a fork-lift using said slots.
21. A pallet according to claim 20, further comprising a plurality of slot-inserts, each slot-insert being configured to fit in a slot such that an outer surface of the slot-insert is substantially flush with the surface of the beam adjacent the slot.
22. A pallet according to claim 21, wherein the outer surface of the slot-insert includes one or more slat-recesses.
23. A pallet according to any of claims 15 to 22, wherein the beams and slats are made of plastic.
24 A stillage comprising a pallet according to any of claims 15 to 23 and at least two arms, each arm being connected to the base at a first end and extending away from the base, and a plurality of slats, each slat extending between at least two arms to define, at least in part, a side wall of the stillage, and wherein each arm comprises one or more slat-recesses in which a portion of a slat is received such that the side wall may be broken down and built up by removing the slats from and inserting the slats into said one or more recesses.
25. A stillage according to claim 24, wherein the first end of each beam is configured to form two interlocking joints at the same time, such that the first end of each beam is configured to form the interlocking joint with the second end of another beam and to form another interlocking joint with the first end of each arm.