WO2008035341A2

WO2008035341A2 - Modular pallet assembly

Info

Publication number: WO2008035341A2
Application number: PCT/IL2007/001157
Authority: WO
Inventors: Nir Hadar
Original assignee: Polymer Logistics B.V.
Priority date: 2006-09-20
Filing date: 2007-09-20
Publication date: 2008-03-27
Also published as: IL178225A0; WO2008035341A3

Abstract

A modular pallet assembly for use with a pallet lifting tool includes load-bearing platforms removably engaged with a support structure. The support structure is formed with bridge elements deployed such that, when the pallet lifting tool is inserted in a first manner, the pallet lifting tool engages the bridge elements thereby lifting the combined pallet assembly as a unit and, when the pallet lifting tool is inserted in a second manner at roughly the same height above an underlying surface as in the first manner, the pallet lifting tool acts directly on at least one of the platforms, separating the platform from the support structure.

Description

Modular Pallet Assembly

FEBLD AND BACKGROUND OF THE INVENTION

The present invention relates to a modular pallet assembly and, in particular, it concerns an assembly in which a plurality of smaller pallets or dollies are mounted on a common pallet support structure to allow lifting of either the combined assembly as a unitary larger pallet or of the individual sub-units.

Palletized shipping has become the standard technique for moving produce of a wide variety of kinds. The use of a pallet, i.e., a load bearing surface or "deck" supported above an underlying surface by spacer elements, allows the use of mechanized lifting equipment such as fork-lift trucks or pallet jacks to efficiently move stacks of produce for storage, loading and unloading. For maximum efficiency, it is preferable to use relatively large pallets to allow moving of large stacks of produce at one time. On the other hand, at the end point of a distribution chain, such as in a retail outlet, large pallets are often inconvenient to handle. For example, for supply of fruit and vegetables to retail stores, it is common in certain countries to use "EUR" pallets of 120x80 centimeters. However, crates of such dimensions would often be overly large for the required quantities of produce for a single retail store, and may not readily be negotiated along relatively narrow aisles of the store. Instead, it is common to employ smaller crates, for example, 60x40 centimeters, which are arranged in four separate stacks on the 120x80 centimeter pallet. A distribution center typically receives pallets with four stacks of 60x40 crates of each type of produce. The stacks are removed and reassembled into combinations on each pallet corresponding to the produce ordered by each given retail outlet. These loaded pallets are then transported from the distribution center to the retail outlet where they are separated on arrival into individual crates or sub-stacks of more manageable 60x40 centimeter dimensions. Clearly, it would be advantageous when separating the contents of the large pallet to move each separate stack as a unit. To this end, various suppliers provide "quarter pallets" immediately above the full-size pallet which would allow lifting of each individual stack. In practice, however, this arrangement often fails to provide the desired functionality. Specifically, many retail outlets, and particularly smaller stores, do not have forklift equipment capable of lifting the quarter pallets from a starting position raised up above floor level. Instead, the commonly available equipment is a manual or powered pallet jack which requires ground contact near the end of the tines to lift a load and cannot be used to lift a pallet positioned on top of another pallet. Instead, the only available option is often labor intensive manual unloading of the pallet crate-by-crate.

There is therefore a need for a modular pallet assembly which would unite a plurality of stacks for handling as a full-size pallet, but would also allow "ground- level" insertion of lifting equipment such as a pallet jack to remove each individual stack as a separate unit.

SUMMARY OF THE INVENTION

The present invention is a modular pallet assembly which unites a plurality of stacks for handling as a full-size pallet, but also allows "ground-level insertion" of lifting equipment such as a pallet jack to remove one or more individual stack independently.

According to the teachings of the present invention there is provided, a modular pallet assembly for use with a pallet lifting tool, the modular pallet assembly comprising: (a) a plurality of load-bearing platforms, each of the platforms including a load bearing deck and a plurality of spacer elements deployed below the load bearing deck for supporting the load bearing deck above an underlying surface to allow insertion of the pallet lifting tool; and (b) a support structure configured to receive the plurality of platforms engaged thereon to form a combined pallet assembly, wherein the support structure is formed with a plurality of bridge elements deployed such that, when the pallet lifting tool is inserted in a first manner, the pallet lifting tool engages the bridge elements thereby lifting the combined pallet assembly as a unit and, when the pallet lifting tool is inserted in a second manner at substantially the same height above an underlying surface as in the first manner, the pallet lifting tool acts directly on at least one of the platforms, separating the platform from the support structure.

According to a further feature of the present invention, the plurality of load- bearing platforms is a set of similar platforms.

According to a further feature of the present invention, the plurality of load- bearing platforms is a set of four similar platforms, and wherein the support structure is configured to receive the platforms in a two-by-two arrangement.

According to a further feature of the present invention, the platforms are implemented as pallets.

According to a further feature of the present invention, the platforms are implemented as dollies. According to a further feature of the present invention, the platforms are implemented as boxes.

According to a further feature of the present invention, the bridge elements are deployed so as to extend generally in a first direction such that, when the pallet lifting tool is inserted generally perpendicular to the first direction, the pallet lifting tool engages the bridge elements and, when the pallet lifting tool is inserted generally parallel to the first direction, the pallet lifting tool does not engage the bridge elements.

According to a further feature of the present invention, the support structure further includes a plurality of ground-contact skids extending generally parallel to the first direction.

According to a further feature of the present invention, the first and second manners of insertion are ground-level insertion.

According to a further feature of the present invention, the load bearing platforms are configured, when used alone, to support a load at a first spacing above an underlying surface, and wherein the support structure is configured such that the combined pallet assembly supports a load at a second spacing above an underlying surface, the second spacing being no more than fifty percent greater than the first spacing.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:

FIG. IA is an isometric view of a modular pallet assembly, constructed and operative according to the teachings of the present invention, illustrating insertion of a pallet lifting tool in a first direction for lifting the entire modular pallet assembly;

FIG. IB is an isometric view of the modular pallet assembly of Figure IA illustrating insertion of a pallet lifting tool in a second direction for lifting one or more load bearing platform without an underlying support structure;

FIG. 2A is an isometric view of an alternative implementation of an underlying support structure, constructed and operative according to the teachings of the present invention, for use with an alternative design of load bearing platform;

FIG. 2B is an isometric view of a modular pallet assembly, constructed and operative according to the teachings of the present invention, including the underlying support structure of Figure 2A together with corresponding load bearing platforms;

FIG. 2C is an isometric view similar to Figure 2B illustrating the group of load bearing platforms lifted away from the underlying support structure;

FIG. 2D is a side view of the modular pallet assembly of Figure 2B illustrating a subgroup of the load bearing platforms being lifted away from the underlying support structure;

FIG. 3 is an isometric view illustrating a set of load bearing platforms of a further design and a corresponding underlying support structure for implementing a modular pallet assembly constructed and operative according to the teachings of the present invention; FIG. 4 is an isometric view illustrating an alternative implementation of an underlying support structure for implementing a modular pallet assembly constructed and operative according to the teachings of the present invention with the load bearing platforms of Figure 3; FIG. 5 is an isometric view illustrating an implementation of the modular pallet assembly of the present invention in which the load bearing platforms are implemented as dollies;

FIG. 6A is an isometric view similar to Figure IA illustrating the height of "ground level insertion" of a pallet lifting tool according to the teachings of the present invention; and

FIG. 6B is an isometric view illustrating the required height of insertion of a pallet lifting tool for lifting the load bearing platforms of Figure IA when they are positioned on top of a conventional underlying pallet.

DESCRIPTION OF TKDB PREFERRED EMBODIMENTS The present invention is a modular pallet assembly which unites a plurality of stacks for handling as a full-size pallet, but also allows "ground-level insertion" of lifting equipment such as a pallet jack to remove one or more individual stack independently.

The principles and operation of modular pallet assembly according to the present invention may be better understood with reference to the drawings and the accompanying description.

Referring now to the drawings, Figures IA and IB illustrate a first implementation of a modular pallet assembly 10, constructed and operative according to the teachings of the present invention, for use with a pallet lifting tool. Generally speaking, this and other implementations of the modular pallet assembly of the present invention include a plurality of load-bearing platforms and a support structure configured to receive the platforms engaged thereon to form a combined pallet assembly. The support structure is formed with a plurality of bridge elements deployed such that, when the pallet lifting tool is inserted in a first manner, the pallet lifting tool engages the bridge elements thereby lifting the combined pallet assembly as a unit and, when the pallet lifting tool is inserted in a second manner at substantially the same height above an underlying surface as in the first manner, the pallet lifting tool acts directly on at least one of the platforms, separating the platform from the support structure.

Thus, referring to Figures IA and IB, there is shown a support structure 12 with a plurality of bridge elements 14, best seen in Figure IB. Bridge elements 14 are deployed roughly parallel to each other extending in a first direction, in this case across the narrower dimension of support structure 12. When a pallet lifting tool, represented by tines 100, is inserted generally perpendicular to the first direction as shown in Figure IA, the pallet lifting tool engages bridge elements 14 thereby lifting support structure 12 as a unit together with the load bearing platforms 16 which are deployed thereon. When the pallet lifting tool is inserted generally parallel to the first direction as shown in Figure IB, the pallet lifting tool does not engage the bridge elements. In this case, the pallet lifting tool acts directly on whichever of the load bearing platforms it engages, lifting them away from the support structure and rendering them separable for handling as individual pallets.

At this stage, it will already be apparent that the modular pallet assembly of the present invention provides clear advantages over the use of a conventional full- size pallet as a base. Specifically, referring to Figures 6A and 6B, it will be noted that point of entry for a pallet lifting tool in both modes of lifting according to the present invention (Figure 6A) remains a ground-level insertion, i.e., at a level H₀ no greater than the vertical height of the load bearing platforms. This clearly contrasts with the use of quarter pallets positioned on a regular full-size pallet base (Figure 6B) which requires a raised point of entry at level H₁ in order to lift the quarter pallets on which each individual stack is assembled. As mentioned above, this raised point of entry precludes the use of a simple pallet jack, thereby forcing manual disassembling of each stack on arrival at many retail outlets where forklift equipment is unavailable. This and other advantages of the present invention will become clearer from the subsequent detailed description.

At this point, it will be helpful to define certain terminology as used herein in the description and claims. Firstly, reference is made to "load bearing platforms". This phrase is used herein to refer generically to any and all loadable structure which includes a load bearing deck and a plurality of spacer elements deployed below the load bearing deck for supporting the load bearing deck above an underlying surface to allow insertion of a pallet lifting tool. "Load bearing platforms" thus defined include, but are not limited to, pallets, dollies and pallet boxes. The "load bearing deck" may be a unitary support surface, with or without ventilation openings, or may be a slatted or otherwise discontinuous set of surfaces which function together to provide a load bearing deck, all as is known in the art. Most preferably, although not necessarily, the spacer elements are separate legs or wheel assemblies without skids interconnecting them. The load bearing platforms may be made from any material or combination of materials suited for this purpose. Certain particularly preferred implementations as illustrated here are formed from molded polymer materials.

The terms "crate", "box", "container" and "tray" are used herein interchangeably to refer to the containers in which produce is loaded on top of each load bearing deck. The containers are preferably stackable and form independent stacks of produce based on each of the load bearing platforms.

The term "pallet lifting tool" is used generically to refer to tools of all kinds which lift pallets by inserting tines underneath the load bearing deck. The term "forklift" is used to refer to pallet lifting tools in which the ends of the tines are unsupported, whereas "pallet jack" is used to refer to tools in which at least part of a load on each tine is transferred to a wheel deployed beneath the tine. As discussed above, forklifts are typically able to lift loads by insertion at above-ground insertion levels whereas pallet jacks are limited to ground-level insertion.

In this context, "ground-level insertion" is used to refer to a level of insertion for tines of a pallet lifting tool which either starts at the level of the underlying "ground" surface, or requires mounting a small obstacle such as posed by the skid of a pallet which can be traversed by a pallet jack without significant difficulty. "Ground-level insertion" thus occurs at a height above the underlying surface no greater than the vertical height of the load bearing platform itself. As already mentioned, the pallet assembly of the present invention provides several advantages over the shipping pallet of the prior art such as the use of a full sized shipping pallet for the storage and transportation of items and then using a smaller sized pallet to move the items through the aisles of the store. By non-limiting example, a manufacturer may ship a pallet support structure with load bearing platforms all loaded with the same product to a wholesaler or distribution center. The distribution center may then easily remove the loaded top-deck elements from the original pallet support structure and assemble a loaded pallet support structure having top-deck elements loaded with a different set of products for transportation to the sales outlet. Once at the sales outlet, the invention allows lifting and moving each set of products to the appropriate area of the store using a simple pallet jack without having to move the entire full sized pallet, and all of the sets of items, through the store together. Nor is it necessary to unload each set of items from the full sized pallet and re-load them on to an alternative mode of in-store transport such as a hand truck or dolly. Referring now again to Figures IA and IB, the particularly preferred embodiment illustrated herein is configured with four load bearing platforms 16 which are all similar and interchangeable, and which engage support structure 12 in a two-by-two configuration. For example, each load bearing platform 16 may advantageously be implemented as a 60x40 centimeter "quarter pallet" for use with a standard EUR 120x80 size support structure, thereby forming a combined pallet assembly of standard size. It should be appreciated however that the present invention is not limited to such embodiments, and that embodiments with substantially any number of top-deck elements are within the scope of the present invention. In fact, the top-deck elements need not be similar. Thus, for example, a single large load-bearing platform (not shown) may be deployed on one half of pallet support structure 12 while two smaller load bearing platforms are deployed on the other half. In most preferred cases, the outline shape of the decks of the load bearing platforms are rectangular. Square decks and/or support structures are hereby defined as a special case falling within the definition of "rectangular".

In the embodiment shown here, each load bearing platform 16 is a pallet formed with six legs 18. Two pairs of legs 18 are deployed to define between them a small spacing 20 which cooperates with an upstanding wall 22 of support structure 12, thereby at least partially defining the engaged position of the pallets 16. Wall 22 is here combined as the base of bridge elements 14. Bridge elements 14 themselves are preferably formed with engagement or centering features for helping align and maintain correct positioning of the load bearing platforms. Thus, in this case, bridge elements 14 are formed with inclined abutment surfaces 24 which cooperate with corresponding features on the underside of pallets 16, helping to center them in the required positions.

Support structure 12 preferably also includes one or more base element 26 which interconnects bridge elements 14. In certain embodiments, base elements 26 are implemented as a number of parallel skids extending perpendicular to the direction of extension of the bridge elements 14, such as will be illustrated below with reference to Figure 2A. In the embodiment of Figures IA and IB, base element 26 is formed as an open frame. Openings or spaces are preferably formed in or between the base element(s) in such a manner as to allow the assembled pallet assembly to be lifted using a pallet jack. Parenthetically, it should be noted however that, in cases where the full-size combined pallet is always to be lifted by a forklift and only load bearing platforms need be lifted by a pallet jack, a full, non-apertured base element may be used.

Most preferably, base element 26 provides additional, or alternative, features for engaging legs 18 of pallets 16 to prevent slipping of the pallets 16 when engaged on support structure 12. In this case, base element 26 is formed with various upwardly projecting tabs or stops 28 positioned to prevent lateral slipping of pallets 16. The form of base element 26 and the positioning of any stops 28 is chosen to avoid interfering with insertion of a pallet jack in either of the insertion directions. Most preferably, parts of base element 26 to be crossed by the pallet jack are formed as low-lying portions with sloped or ramp-like edges to facilitate insertion of the pallet jack.

It is typically preferred that support structure 12 allows insertion of a pallet lifting tool from each of the two opposite sides of the structure in each of the first and second directions, although one-sided-entry structures also fall within the scope of the invention. In certain cases, if the primary mode of use will be to remove only a single stack at a time, it may be desirable to provide a central wall (not shown) perpendicular to bridge elements 14 where the pallet edges meet. This wall would prevent insertion of a pallet lifting tool beyond the midline of the support structure, thereby preventing accidental toppling of a stack by operating a lifting tool inadvertently inserted under part of the further pallet. According to this option, two sided access would be required in order to remove the stacks.

It will be noted that base element(s) 26 preferably provides the ground contact surfaces for the combined pallet assembly, and that the individual load bearing platforms sit on top of the base element. At the same time, in order to maintain the ground-level insertion for each insertion direction of a pallet lifting tool, the height added to the pallets by support structure 12 is significantly less than the height of the load bearing platforms when standing alone. Thus, support structure 12 is preferably configured such that the combined pallet assembly supports a load at a spacing above an underlying surface which is no more than fifty percent greater than the spacing generated by platforms 16 when used alone. Typically, support structure 12 adds no more than about 25 or 30 percent to the height of platforms 16 when standing alone.

Although bridge elements 14 are here shown extending across the shorter dimension of support structure 12, thereby defining that short-side-entry of a pallet lifting tool lifts the entire structure, it will be clear that the structure may be implemented with the bridge elements extending along the longer dimension if preferred.

Pallet support structure 12 may be formed as a single integrally formed element, or may be an assembly of several interconnected elements. The support structure may be formed from any material or combination of materials having mechanical properties suitable for the intended function. Examples of materials which may be suitable include, but are not limited to, molded polymers, metal and wood. Most preferred implementations of pallet support structure 12 are formed from polymer materials. At this stage, the function of modular pallet assembly 10 will be clear. When assembled, modular pallet assembly 10 may be lifted as a unit by insertion of pallet lifting tool 100 in a first direction, as illustrated in Figure IA, thus allowing handling of the assembly in a manner similar to a conventional full-size pallet. When it is desired to load, unload or re-load one or more individual load bearing platform and its load from the assembly, a pallet lifting tool 100 is inserted in a second direction, as illustrated in Figure IB. In both cases, the insertion is preferably a ground-level insertion, as defined above, facilitating the use of pallet jacks is desired.

Turning now to the remaining Figures 2A-5, there are shown four variant implementations of modular pallet assembly 10 designated 200, 300, 400 and 500, respectively. Each of these implementations is essentially similar both in structure and function to modular pallet assembly 10 described thus far, and analogous elements are labeled similarly with addition of the value of the reference numeral of that implementation. In each case, for conciseness of presentation, the description below will address primarily the features which differ from the implementation of Figures IA and IB. Regarding all other features, the description above of modular pallet assembly 10 should be considered to refer mutatis mutandis to the other implementations .

Turning now to Figures 2A-2D, this shows a modular pallet assembly 200, constructed and operative according to the teachings of the present invention, implemented with a different type of load bearing platform, in this case, a pallet 216 with legs 218 at its corners and in the middle of its longer sides. In this case, part of the engagement between pallets 216 and support structure 212 is provided by a pair of walls 222, located on either side of legs 218 in the middle of the longer sides of the pallet. The top edges of walls 222 engage corresponding recessed channels 232 in the underside of the pallet decks, as best seen in Figure 2D. Additional projections 234 formed on walls 222 engage corresponding recesses (not shown) to enhance resistance to sliding along the recessed channels.

Additional or alternative engagement between pallets 216 and support structure 212 is provided by sockets 230 formed in base elements 226 which are shaped and positioned to be engaged by the ends of legs 218. Base elements 226 themselves are here implemented as a set of parallel skids. In all other respects, the structure and function of modular pallet assembly 200 is analogous to that of modular pallet assembly 10 above. As in all other implementations, removal of pallets 216 from support structure 212 can be performed all at once as illustrated in Figure 2C, or one or more at a time as illustrated in Figure 2D.

Turning now to Figure 3, this shows a modular pallet assembly 300, constructed and operative according to the teachings of the present invention. It should be noted that the present invention may be implemented for a wide range of commercially available load bearing platforms without modification of the load bearing platforms simply by designing a suitable support structure. My way of a first non-limiting example, Figure 3 shows an implementation for pallets 316 which correspond to the "Plastic Display Quarter Pallet" model P0604A commercially available from CHEP^® (Orlando, FL, USA). In this case, support structure 312 is formed with a set of walls 322, bridge elements 314 and additional projections 334 deployed to fit between the legs 318 of the pallets and engage the underside of the pallet's deck. Similarly, base elements 326 are formed with features to engage the bottoms of legs 318, in this case formed as projections 336 configured to engage the hollow ends of the legs of the pallets 316. Here again, base elements 326 are implemented as a set of parallel skids. In all other respects, the structure and function of modular pallet assembly 300 is analogous to that of modular pallet assemblies 10 and/or 200 above.

Turning now to Figure 4, this shows an alternative implementation of a modular pallet assembly 400, again employing the aforementioned CHEP^® pallets, here designated 416. In this case, support structure 412 is implemented without projections to engage the hollow legs. Instead, a simple arrangement of projecting stops 428, together with walls 422 are used to define the intended position of each pallet and prevent sliding. Finally, turning to Figure 5, as mentioned earlier, the present invention is not limited to use with pallets, and may instead be used with pallet boxes or dollies. By way of example, Figure 5 illustrates an implementation of a modular pallet assembly 500 in which load bearing platforms 516 are dollies supported by wheel assemblies 538. In this case, at least part of the engagement configuration between the dollies and support structure 512 preferably includes recesses 540 shaped and positioned for receiving wheel assemblies 538, and to prevent the wheel assemblies from rolling and/or swiveling. The functionality of this implementation remains as before, namely, that the entire assembly functions as a full-size pallet when lifted by insertion in a first direction, in this case, from the shorter side, while lifting by insertion of a pallet lifting tool from the longer side separates one or more of the dollies, with any stack loaded thereon, from the assembly. Once separated, this implementation provides the additional option of lowering the dolly onto its wheels for wheeling to the desired location while freeing up the pallet jack for other tasks. In all other respects, the structure and function of modular pallet assembly 500 is analogous to that of modular pallet assemblies 10, 200, 300 and/or 400 described above.

It will be appreciated that the above descriptions are intended only to serve as examples, and that many other embodiments are possible within the scope of the present invention as defined in the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A modular pallet assembly for use with a pallet lifting tool, the modular pallet assembly comprising:

(a) a plurality of load-bearing platforms, each of said platforms including a load bearing deck and a plurality of spacer elements deployed below said load bearing deck for supporting said load bearing deck above an underlying surface to allow insertion of the pallet lifting tool; and

(b) a support structure configured to receive said plurality of platforms engaged thereon to form a combined pallet assembly, wherein said support structure is formed with a plurality of bridge elements deployed such that, when the pallet lifting tool is inserted in a first manner, the pallet lifting tool engages said bridge elements thereby lifting said combined pallet assembly as a unit and, when the pallet lifting tool is inserted in a second manner at substantially the same height above an underlying surface as in said first manner, the pallet lifting tool acts directly on at least one of said platforms, separating said platform from said support structure.

2. The modular pallet assembly of claim 1, wherein said plurality of load- bearing platforms is a set of similar platforms.

3. The modular pallet assembly of claim 1, wherein said plurality of load- bearing platforms is a set of four similar platforms, and wherein said support structure is configured to receive said platforms in a two-by-two arrangement.

4. The modular pallet assembly of claim 1, wherein said platforms are implemented as pallets.

5. The modular pallet assembly of claim 1, wherein said platforms are implemented as dollies.

6. The modular pallet assembly of claim 1, wherein said platforms are implemented as boxes.

7. The modular pallet assembly of claim 1, wherein said bridge elements are deployed so as to extend generally in a first direction such that, when the pallet lifting tool is inserted generally perpendicular to said first direction, the pallet lifting tool engages said bridge elements and, when the pallet lifting tool is inserted generally parallel to said first direction, the pallet lifting tool does not engage said bridge elements.

8. The modular pallet assembly of claim 7, wherein said support structure further includes a plurality of ground-contact skids extending generally parallel to said first direction.

9. The modular pallet assembly of claim 1, wherein said first and second manners of insertion are ground-level insertion.

10. The modular pallet assembly of claim 1, wherein said load bearing platforms are configured, when used alone, to support a load at a first spacing above an underlying surface, and wherein said support structure is configured such that said combined pallet assembly supports a load at a second spacing above an underlying surface, said second spacing being no more than fifty percent greater than said first spacing.