WO2002007570A1

WO2002007570A1 - Pallet use-conversion system

Info

Publication number: WO2002007570A1
Application number: PCT/US2001/021698
Authority: WO
Inventors: Michael J. Calleja
Original assignee: Calleja Michael J
Priority date: 2000-07-25
Filing date: 2001-07-10
Publication date: 2002-01-31
Also published as: AU2001271959A1

Abstract

A pallet-conversion system (100) comprises a pair of wooden pallets stacked a few feet apart and parallel. A bottom one (102) of the two pallets is fitted with four caster-wheel assemblies that cup each of the four bottom corners. A strap (108) runs around the outside of the four caster-wheel assemblies and locks them in place. The upper pallet (104) has four corner-adapters (106) that cup each of its four corners. A second strap locks all these in place. Both the caster-wheel assemblies and the corner-adapters have two pockets each that receive 2-by-4 sections of lumber (114-121). Such lumber is cut to a length that gives the desired table-height of the upper pallet.

Description

PALLET USE-CONVERSION SYSTEM

BACKGROUND OF THE INVENTION

Field of the Invention The present invention relates to material-handling pallets, and more particularly to caster-wheel attachments and staging adapters that convert ordinary wooden pallets into roll-around carts and other useful equipment.

Description of Related Art

Wooden pallets have become ubiquitous. Heavy material loads are easily moved about by forklifts, and the standard pallet helps a forklift maneuver its lifting tongs under the load. Very often pallets are left around after their job is done . Their use in other applications is very limited, probably because they are so specialized to their use with forklifts. What is needed is a way to put pallets to work in other jobs. An otherwise unused pallet could represent a major cost savings in such other uses.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a caster-wheel assembly that can be attached to the four corners of a pallet.

Another object of the present invention is to provide a staging adapter that can be fitted to each pallet level to create a stack. /Another object of the present invention is to provide a conversion system that allows two pallets to be converted into a two-level roll-around cart.

Briefly, a pallet-conversion system embodiment of the present invention comprises a pair of wooden pallets stacked a few feet apart and parallel. A bottom one of the two pallets is fitted with four caster-wheel assemblies that cup each of the four bottom corners . A strap runs around the outside of the four caster-wheel assemblies and locks them in place. The upper pallet has four corner- adapters that cup each of its four corners. A second strap locks all these in place. Both the caster-wheel assemblies and the corner-adapters have two pockets each that receive 2-by-4 sections of lumber. Such lumber is cut to a length that gives the desired table-height of the upper pallet.

An advantage of the present invention is that a system is provided that makes useful equipment from otherwise unused pallets .

Another advantage of the present invention is that a corner-adapter is provided that allows pallet shelving to be assembled with 2-by-4 framing.

A further advantage of the present invention is that caster-wheel assemblies are provided that can be used to convert a pallet into a roll-around cart or tray. The above and still further objects, features, and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof, especially when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view of a pallet-conversion system embodiment of the present invention; Figs . 2A and 2B are perspective views of how the typical caster-wheel assemblies of Fig. 1 are fitted to a pallet;

Fig. 3 is a perspective view of a roll-around cart embodiment of the present invention;

Fig. 4 is a perspective view of a caster-wheel assembly embodiment of the present invention for use with a pallet;

Fig. 5 is a perspective view of an interstage corner assembly embodiment of the present invention for use with a pallet;

Fig. 6 is a perspective view of a pallet use- conversion system embodiment of the present invention with a bottom wheeled stage and a top extended stage; Fig. 7 is a perspective view of a pallet-corner adapter embodiment of the present invention showing the clips that hold it to a pallet;

Fig. 8 is a perspective view of a pallet-corner adapter embodiment of the present invention showing the handles and their attachment to the clips;

Fig. 9 is a perspective view of a caster-wheeled pallet-corner adapter embodiment of the present invention; and

Fig. 10 is a bottom perspective view of a pallet- corner adapter embodiment of the present invention showing both upper and lower post-extension pockets and the two handles and clips in their opened position for attachment top a pallet.

DETAILED DESCRIPTION OF THE INVENTION

Fig. 1 illustrates a pallet-conversion system embodiment of the present invention, referred to herein by the reference numeral 100. In this example, a roll-around cart suitable for use in a garden nursery is shown assembled. The pallet-conversion system 100 comprises a lower wooden pallet 102 under an upper wooden pallet 104. A set of four caster-wheel assemblies 106 are held by a taut strap 108 to each of the four bottom corners of the lower wooden pallet 102. Similarly, set of four stacking adapters 110 are held by a second taut strap 112 to each of the four bottom corners of the upper wooden pallet 104. Alternatively, the strapping could be eliminated by screwing each of the four caster-wheel assemblies 106 and the four stacking adapters 110 to their respective wooden pallets.

One or more staging levels can be easily realized. The four caster-wheel assemblies 106 and the four stacking adapters 110 each have two pockets that receive a set of eight pieces of 2-by-4 lumber 114-121. The lumber is cut to result in the desired table height of the upper pallet 104.

In a commercial product embodiment, the pallet- conversion system 100 would not ordinarily include the wooden pallets 102 and 104. Otherwise-unused pallets would be put to work with this conversion system.

Figs . 2A and 2B show how the typical caster-wheel assemblies of Fig. 1 are fitted to a pallet. A one-level roll-around cart 200 is illustrated up-side-down so all four wheels and corners can be seen at once. The cart 200 comprises a wooden pallet 202 fitted with a set of four caster-wheel assemblies 204-207 at each bottom corner. Each caster-wheel assembly 204-207 is preferably constructed of heavy sixteenth-inch thick steel flat bar welded into two 2-by-4 lumber pockets and a corner ledge. A standard caster wheel set is bolted to the center of the corner ledge area.

In Fig. 2B, the caster-wheel assemblies 204-207 are attached with a strap 208 that is tightened-on with a cinch 210. Fig. 3 illustrates a roll-around cart embodiment of the present invention, referred to herein by the reference numeral 300. The cart 300 comprises a lower wooden pallet 302 under an upper wooden pallet 304. A set of four caster-wheel assemblies 306 are held by a taut strap 308 to each of the four bottom corners of the lower wooden pallet 302. Similarly, a set of four stacking adapters 310 are held by a second taut strap to each of the four bottom corners of the upper wooden pallet 304. The four caster- wheel assemblies 306 each have two pockets that receive a set of struts, e.g., eight pieces of 2-by-4 lumber 314-321. The four stacking adapters 310 are such that additional stages can be built up on top. The inter-stage lumber can be cut to any desired length, albeit all eight pieces per stage are usually the same length.

In alternative embodiments of the present invention, the cart 300 would not ordinarily be sold with the wooden pallets 302 and 304 or the eight pieces of 2-by-4 lumber 314-321.

Fig. 4 represents a caster-wheel assembly 400 for use with a pallet. The caster-wheel assembly 400 includes a rubber or plastic wheel 402 mounted on a caster gimbal 404. This attaches to a metal base plate 406. A pair of strut pockets 408 and 410 are made of metal welded to the base plate 406 and are sized to firmly hold pieces of dimensional lumber used as interstage struts, e.g., common 2-by-4 pieces. Fig. 5 represents an interstage corner assembly 500 for use with a pallet. The interstage corner assembly 500 includes a metal base plate 502. A pair of upper strut pockets 504 and 506, and a pair of lower strut pockets 508 and 510 are made of metal welded to the base plate 502. Such pockets are sized to firmly hold pieces of dimensional lumber used as interstage struts, e.g., common 2-by-4 pieces.

The embodiments shown herein have used rectangular cross-section lumber and pockets for the staging of the pallets with post extensions. Round dowels and matching round holders could be used as well. Fig. 6 represents a pallet use-conversion system embodiment of the present invention, and is referred to herein by the general reference numeral 600. It uses a different method of attachment to the pallets, and is preferred in applications where the use of a strap is impractical or inconvenient. The system 600 stages a pair of wooden pallets 602 and 604 apart with a set of four post extensions 606-609. The upper pallet 602 is fitted with a set of four pallet-corner adapters 610-613. Each of which preferably lock or otherwise attach firmly to the corners of the wooden pallet.

The four pallet-corner adapters 610-613 each have a pair of handle-operated locks, as represented by clip-locks 614 and 616. A bottom post-extension pocket 618 receives post extension 606 and is typical of all four. A top post- extension pocket 620 receives another higher-stage post extension (not shown) and is also typical of all four.

The particular pallet lock-on devices shown here use C-shaped clips that are rotated out of the way when the pallet-corner adapters 610-613 are slipped on each corner. The C-shaped clips are then rotated back to clamp the base of each adapter to one of the four bottom plates 621-624 in the pallet structure. These bottom plates are typically "one-by-four" or "one-by-six" white lumber. Pallets constructed this way are ubiquitous.

The lower pallet 604 has four caster-wheeled corner adapters 626-629. Such wheels are intended to roll about in any direction on a floor. The extension posts 606-609 slip into pockets on the corner adapters 626-629 and can be locked in by tapers, threads, set screws, etc. Ordinary plumbing pipe with or without threads could be used for the extension posts 606-609. If polyvinyl chloride (PVC) pipes were used for the extension posts 606-609, and the corner adapters 626-629 or its pockets were also made of PVC, then common PVC-glue could be used to permanently assemble system 600. More details are provided for the wheeled adapter in connection with Fig. 9. Fig. 7 provides greater details regarding a typical pallet-corner adapter 700. The general construction is of metal or plastic for strength, e.g., steel, aluminum, or polycarbonate. A base plate 702 includes two slots 704 and 706 that allow a pair of respective C-shaped clips 708 and 710 to be rotated on corresponding axles with handles 712 and 714. For example, a bolt 716 is used for both axles. A wall 718 supports a post pocket 720. A bottom post pocket is possible too, the perspective of Fig. 7 obscures the view. In operation, a structural piece of a pallet is clamped between clip 708 and a stationary clip 722. On an adjacent side, an orthogonal structural piece of the same pallet is clamped between clip 710 and another stationary clip 724. Fig. 8 provides more details regarding a pallet-corner adapter 800 like that of Fig. 7. A base plate 802 includes two slots 804 and 806 that allow a pair of respective C- shaped clips 808 and 810 to be rotated on corresponding axles with handles 812 and 814. For example, a bolt 816 is used for both axles. A wall 818 supports a post pocket 820. A bottom post pocket 822 is possible too. In operation, a structural piece of a pallet is clamped between clip 808 and a stationary clip 824. On an adjacent side, an orthogonal structural piece of the same pallet is clamped between clip 810 and another stationary clip 826. Fig. 9 provides more details regarding a wheeled pallet-corner adapter 900. A base plate 902 includes two slots 904 and 906 that allow a pair of respective C-shaped clips 908 and 910 to be rotated on a bolt 912 with handles 914 and 916. A wall 918 supports a post pocket 920. A bottom post pocket 922 is below. In operation, a structural piece of a pallet is clamped between clip 908 and a stationary clip 924. On an adjacent side, an orthogonal structural piece of the same pallet is clamped between clip 910 and another stationary clip 926. A caster swivel 928 supports a wheel 930. Alternatively, the wheel can be mounted to a fixed axle. Fig. 10 provides more details regarding a pallet- corner adapter 1000 like that of Fig. 7. A base plate 1002 includes two slots 1004 and 1006 that allow a pair of respective clips 1008 and 1010 to be independently rotated on a bolt axle 1012 with handles 1014 and 1016. A wall 1018 supports an upper post pocket 1020 and a bottom post pocket 1022. In operation, a structural piece of a pallet is clamped between clip 1008 and a stationary clip 1024. On an adjacent side, an orthogonal structural piece of the same pallet is clamped between clip 1010 and another stationary clip 1026.

Although particular embodiments of the present invention have been described and illustrated, such is not intended to limit the invention. Modifications and changes will no doubt become apparent to those skilled in the art, and it is intended that the invention only be limited by the scope of the appended claims.

Claims

THE INVENTION CLAIMED IS

1. A pallet use-conversion system, comprising: a set of four pallet-corner adapters; an attachment for securing each one of the four pallet-corner adapters to a wooden pallet at each outside corner; and a post-extension pocket disposed in each of the four pallet-corner adapters for receiving a post; wherein, at least two such said wooden pallets can each be fitted with the set of four pallet-corner adapters and interconnected by a plurality of said posts slipped into corresponding post-extension pockets to create staging.

2. The system of claim 1, wherein: the attachment for securing each one of the four pallet-corner adapters to said wooden pallet comprises an encircling strap which is tightened to lock the whole together.

3. The system of claim 1, wherein: the attachment for securing each one of the four pallet-corner adapters to said wooden pallet comprises a clip that is rotated parallel to said pallet by a handle to engage a structural member of said pallet.

4. The system of claim 1, wherein: the attachment for securing each one of the four pallet-corner adapters to said wooden pallet comprises an orthogonally disposed pair of clips that are each rotated parallel to said pallet by respective handles to engage adjacent structural members of said pallet at a corresponding corner.

5. The system of claim 1, wherein: the post-extension pocket includes top and bottom sections for accommodating staging posts above or below said pallet.

6. The system of claim 1, further comprising: a base-plate assembly with a corner pocket for receiving a corner of said pallet, and for mounting of the post-extension pocket.

7. The system of claim 6, further comprising: a wheel mounted underneath the base-plate assembly for providing movement of said pallet over a floor.

8. The system of claim 6, further comprising: a caster wheel attached on a swivel underneath the base-plate assembly for providing movement of said pallet over a floor in any direction.

9. A pallet-conversion system, comprising: a first pallet with four corners; a set of four independent caster-wheel assemblies positioned to cup and support the bottoms of each of said bottom corners of the first pallet; and a strap that encircles all of the four independent caster-wheel assemblies and the first pallet, and which is tightened to lock the whole together.

10. The pallet-conversion system of claim 9, further comprising: a set of strut pockets included in each of the four independent caster-wheel assemblies.

11. The pallet-conversion system of claim 10, further comprising: a set of vertical struts that are individually inserted into corresponding ones of the set of strut pockets .

12. The pallet-conversion system of claim 9, further comprising: a second pallet with four corners; a set of four interstage corner assemblies positioned to cup and support the bottoms of each of said bottom corners of the second pallet, and that respectively engage the set of vertical struts; and a second strap that encircles all of the four independent interstage corner assemblies and the second pallet, and which is tightened to lock the whole together.

13. A roll-around cart, comprising: a first pallet with four corners; a set of four independent caster-wheel assemblies positioned to cup and support the bottoms of each of said bottom corners of the first pallet; a set of strut pockets included in each of four independent caster-wheel assemblies; a set of vertical struts that are individually inserted into corresponding ones of the set of strut pockets; a second pallet with four corners; and a set of four interstage corner assemblies positioned to cup and support the bottoms of each of said bottom corners of the second pallet, and that respectively engage the set of vertical struts.

14. A caster-wheel assembly for supporting a bottom corner of a pallet, comprising: a base plate sized to fit under and cage one corner of a pallet; a caster wheel mounted to the base plate; and a strut pocket attached to the base plate for holding an interstage strut.

15. The caster-wheel assembly of claim 14, wherein: the strut pocket provides for a pair of orthogonally disposed dimensional lumber pieces to be received.

16. An interstage corner assembly for supporting a bottom corner of a pallet, comprising: a base plate sized to fit under and cage one corner of a pallet; a lower strut pocket attached to the base plate for capping a first interstage strut from below; and an upper strut pocket attached to the base plate for holding up a second interstage strut above.

17. The interstage corner assembly of claim 16, wherein: the upper and lower strut pockets provide for pairs of orthogonally disposed dimensional lumber pieces to be received.

18. A method for using material pallets, comprising the steps of: strapping a set of four independent caster-wheel assemblies to respectively cup and support bottom corners of a first pallet; strapping a set of four interstage corner assemblies to respectively cup and support bottom corners of a second pallet; and staging said first and second pallets apart from one another with vertical struts that slip into pockets provided in each of said four independent caster-wheel assemblies and each of said four interstage corner assemblies.