A MODULAR PALLET

Abstract

 A modular pallet (10) comprising at least two spaced apart beams (20), at least two pallet segments (30) and at least one brace (70), wherein the beams are located through each of the pallet segments and the at least one brace is located between the at least two pallet segments. A method of manufacturing a pallet, the method including the steps of locating two or more pallet segments over one or more beams, locating one or more braces between two or more pallet segments, wherein the beams are located through each of the pallet segments and a brace is located between the at least two pallet segments.

Description

FIELD OF THE INVENTION

[0001] This invention relates to a pallet. In particular, the invention relates to a modular pallet that can be assembled based on specific requirements and therefore will be described in this context. However, it should be appreciated that the modular pallet can be produced on mass for a single purpose.

BACKGROUND OF THE INVENTION

[0002] Pallets are generally used to both store and transport goods. However, pallets can vary greatly from country to country and industry to industry. For example, there are US pallets, Euro Pallets and Australia pallets all of which have different dimensions. In standard wood pallets, there are two-way entry pallets, four-way entry pallets, no baseboard pallets, close bordered pallets, open bordered pallets. All of these types of wooden pallets are produced to suit certain industries due to their strength and loading characteristics.

[0003] In certain industries, wooden pallets cannot be used due to their permeability characteristics. Accordingly, steel and plastic pallets are often used in biologically sensitive industries such as the medical or food industries. Steel pallets are also used in industries for the carriage of very heavy items that would crush a wooden pallet such as the mining industry. Again, each of these pallets is produced to meet industry requirements.

[0004] Where a specific pallet is required to be produced for a specific use, there is a typically large set-up cost to manufacture the pallet. Further, there is often a training requirement for workers to learn how to manufacture new pallets. This makes the manufacture of pallets with specific requirements expensive compared to mass-produced pallets where economies of scale can be utilised.

OBJECT OF THE INVENTION

[0005] It is an object of the invention to overcome and/or alleviate one or more of the above disadvantages and/or provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

[0006] In one form, although not necessarily the one or only form, the invention resides in a modular pallet comprising :

at least two spaced apart beams; and

at least two pallet segments;

wherein the beams are located through each of the pallet segments.

[0007] Each of the beams is typically made of the same material. The beams may be made of any suitable material such as steel, composite fibre, plastic, or fibreglass. Preferably the beam is made from steel.

[0008] Each beam typically has a constant cross-sectional along its length. Normally, each beam has the same cross-section. The beam may be an I-beam, H-beam, C-beam or hollow rectangular beam. Preferably the beams are either C-beams or I-beams.

[0009] The beams are typically parallel to each other. Two of the beams are typically located adjacent sides of the pallet. Normally there are two, three, four or six beams. The beams may be horizontally spaced. The beams may also be vertically spaced.

[0010] The pallet segments may be made from any suitable material. However, normally, the pallet segments are made from plastic. Any suitable plastic may be used. Normally, the plastic used is polyethylene or polyurethane.

[0011] One or more segment channels may extend through each of the pallet segments. The segment channel may extend entirely through or partially through the pallet segments.

[0012] One or more segments may be connected to one or more beams. One or more end segments may be locked to the beams. The beam may be deformed to lock the end segment to the beam. The beam may have a tab that is deformed to lock the end segment to the beam. The beam may also be locked to other segments.

[0013] A brace may be located between two pallet segments. The brace may be in the form of a bracing plate. One or more bracing channels may extend through each brace.

[0014] Typically the brace is made from a material that has greater strength than the pallet segment. The brace may be made from plastic, composite fibre or steel. Normally the pallet is made from steel.

[0015] Each pallet segment may include a deck and a base which are interconnected by two sides. The deck and the base may also be interconnected by at least one intermediate member. The deck and the base may be interconnected by at least two intermediate members.

[0016] At least two apertures may be formed within a pallet segment. At least three apertures may be formed within the pallet segment. Typically all of the apertures are located between the deck and the base of the pallet segment.

[0017] Normally one or more C-shaped channels are located within each of the sides of a pallet segment. Preferably, one or more C-shaped channels are located through each of the intermediate members of a pallet segment.

[0018] The modular pallet normally has at least two end segments and two tine segments. The modular pallet typically has are at least two end segments, two tine segments and two infill segments.

[0019] The modular pallet may have a tine segment located between an infill segment and an end segment.

[0020] Typically, the end segment has an enclosed front face. Typically, the tine segment has tine opening extending between the two sides and bisecting the base.

[0021] The brace is substantially planar in shape and has slightly smaller outer dimensions than the pallets segments.

[0022] Typically the brace is formed from a deck and a base which are interconnected by two sides. Preferably the deck and the base are interconnected by at least one intermediate member. Preferably the deck and the base of the brace are interconnected by at least two intermediate members.

[0023] Normally, at least two apertures are formed within the brace. Preferably, at least three apertures are formed within the brace. Typically all of the apertures located through the brace are located between the deck and the base.

[0024] Typically, one or more C-shaped channels are located within each of the sides of the brace. Preferably, one or more C-shaped channels are located through each of the intermediate members of the brace.

[0025] In another form, the invention resides in a method of manufacturing a pallet, the method including the steps of:

locating two or more pallet segment over one or more beams

wherein the beams are located through each of the pallet segments

[0026] The method may further include the steps of:

locating the pallet segment over one or more beams whilst the pallet segment is at a temperature greater than ambient temperature;

allowing the pallet segment to cool to shrink fit the pallet segment to the one or more beams.

[0027] The method may further include the step of deforming one or more beams to lock the one or more beams to a pallet segment. The deformation of the beam may occur at a tab formed within the beam. The deformation of the beam may occur using a tool that applies a force to the beam. The tool may apply the force to the beam via or through the pallet segment.

[0028] The pallet segments are typically formed from plastic using a forming machine. The pallet segments may be injection moulded. The pallet segments may be located over the beams shortly after being removed from the forming machine.

[0029] Further features of the invention will become apparent from the detailed description below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] An embodiment of the invention will now be described with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of a pallet according to a first embodiment of the invention.

FIG. 2 is an exploded perspective view of a pallet according to FIG. 1;

FIG. 3 is a perspective view of an end segment of the pallet according to FIG 2;

FIG. 4 is a front view of the end segment as shown in FIG. 3;

FIG. 5 is a perspective view of a tine segment of the pallet according to FIG 2;

FIG. 6 is a front view of the tine segment as shown in FIG. 5;

FIG. 7 is a perspective view of an infill segment of the pallet according to FIG 2;

FIG. 8 is a front view of the infill segment as shown in FIG. 7;

FIG. 9 is a perspective view of a brace of the pallet according to FIG 2 and

FIG. 10 is a front view of the brace as shown in FIG. 9.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

[0031] FIG. 1 and 2 show a first embodiment of a modular pallet 10 that is used to carry goods. The pallet 10 is conducted from four beams 20 and six pallet segments 30.

[0032] The beams 20 provide structural strength for the pallet 10. Each of the four beams are of the same shape with each of the beams being C-shaped steel beams. Each beam 20 has a web 21 with two depending flanges 22. Tabs 23 are located along the web 21 and can be deformed to pivot the tab 23 outwardly from the web 21. The beams 20 are spaced apart and parallel to each other. However, they are orientated differently with

[0033] The six pallet segment 30 provide the platform on which goods are carried and stored. Each pallet segment 30 is integrally formed from injection moulded polypropylene. The six pallet segments are twin walled 31 being supported by both longitudinal reinforcement members 32 and lateral reinforcement members 33. Accordingly, each pallet segment 10 is relatively hollow and accordingly relatively lightweight. The six pallet segments include two end segments 40, two tine segments 50 and two infill segments 60.

[0034] Each end pallet segment 40, as shown in more detail FIG. 3 and FIG. 4, is made up of a deck 41 and a base 42 which are interconnected by two sides 43 and two intermediate members 44. Three apertures 45 are formed within each end pallet segment 40. All of the apertures 45 are located between the deck 41 and the base 42. A C-shaped channel 46 is located within each of the sides 43 and each of the intermediate members 44 for location of respective beams 20. A front face 47 of the end pallet segment 40 is enclosed. Accordingly, the C-shaped channel 46 extends only partially through the sides 43 and the intermediate members 44.

[0035] Each tine pallet segment 50, as shown in more detail FIG. 5 and FIG. 6, is made up of a deck 51 and a base 52 which are interconnected by two sides 53 and two intermediate members 54. Three apertures 55 are formed within each tine pallet segment 50. All of the apertures 55 are located between the deck 51 and the base 52. A C-shaped channel 56 is located within each of the sides 53 and each of the intermediate members 54 for location of respective beams 20. A tine opening 58 extends between the two sides 53 and bisects the base 52.

[0036] Each infill pallet segment 60, as shown in more detail FIG. 7 and FIG. 8, is made up of a deck 61 and a base 62 which are interconnected by two sides 63 and two intermediate members 64. Three apertures 65 are formed within each infill pallet segment 60. All of the apertures 65 are located between the deck 61 and the base 62. A C-shaped channel 36 is located within each of the sides 63 and each of the intermediate members 64 for location of respective beams 20.

[0037] A brace 70, as shown in more detail FIG. 9 and FIG. 10, is located between each of the six segments 30. The brace 70 is substantially planar in shape and has slightly smaller outer dimensions than the pallets segments. The brace 70 is plastic. The brace 70 is formed from a deck 71 and a base 72 which are interconnected by two sides 73 and two intermediate members 74. Three apertures 75 are formed within each brace 70. All of the apertures 75 are located between the deck 71 and the base 72. A C-shaped channel 76 is located within each of the sides 73 and each of the intermediate members 74 for location of respective beams 20.

[0038] To construct the pallet 10, one of the end segments 40 is positioned so that the front face 47 is located adjacent the ground. The four beams 30 are then inserted into respective C-shaped channels 46 located within each of the sides 43 and each of the intermediate members 44. A brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the end segment 40 and recessed within the end segment 40.

[0039] A tine segment 50 is then located over the beams 20 with the beams 20 being located through each of the sides 53 and each of the intermediate members 54. The tine segment 50 is located adjacent the brace 70. The brace 70 is also recessed within the tine segment 50.

[0040] A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the tine segment 70 and recessed within the tine segment 70.

[0041] An infill segment 60 is then located over the beams 20 with the beams 20 being located through each of the sides 63 and each of the intermediate members 64. The infill segment 60 is located adjacent the brace 70. The brace 70 is also recessed within the infill segment 60.

[0042] A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is located adjacent the infill segment 60 and recessed within the infill segment 60.

[0043] A further infill segment 60 is then located over the beams 20 with the beams 20 being located through each of the sides 63 and each of the intermediate members 64. The infill segment 60 is located adjacent the brace 70. The brace 70 is also recessed within the infill segment 60.

[0044] A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is located adjacent the infill segment 60 and recessed within the infill segment 60.

[0045] A tine segment 50 is then located over the beams 20 with the beams 20 being located through each of the sides 53 and each of the intermediate members 54. The tine segment 50 is located adjacent the brace 70. The brace 70 is also recessed within the tine segment 50.

[0046] A further brace 70 is then located over the beams 20 with the beams 20 being located through each of the sides 73 and each of the intermediate members 74. The brace 70 is both located adjacent the tine segment 70 and recessed within the tine segment 70.

[0047] Finally, an end segment 40 is then located over the beams 20 with the beams 20 being located through each of the sides 43 and each of the intermediate members 44. The end segment 40 is located adjacent the brace 70. The brace 70 is also recessed within the end segment 50.

[0048] It should be noted that each of the segments 30 (i.e. end segments 40, tine segments 50 and infill segments 60) are located over the beams 20 whilst at a temperate that is substantially above ambient temperature. The elevated temperature of the segments 30 increases the size of the C-shaped channels 46, 56, 66. This simplifies the application of the segments 30 over the beams 20. Further, once the segments 30 cool, the size of the C-shaped channels 46, 56, 66 reduce to shrink fit the segments 30 onto the beams 20 this holding fast the segments to the beams 20.

[0049] An impact tool (not shown) is used to depress the tabs 23 along the beam 20. This is performed by locating the tool inside the apertures 45, 55, 65 of the segments 30 to a location along the beam 20 where a tab 23 is located. A force is applied to the tab 23 by the tool via a respective side 43, 53, 64 or intermediate member 44, 54, 64 which deforms the tab 23 outwardly with respect to the web 21. This located the tab 23 a respective longitudinal reinforcement member 32 to lock the beam 20 to the segment 30. This operation is performed when the segments 30 are at a temperature that is substantially above ambient temperature which either allows the segment 30 to spring back after contact with the tool, or to deform with the tab 23 further locking the tab 23 to the segment 30.

[0050] The pallet 10 provides a number of advantages. Various sized pallet segments 30 and beam 20 can be produced to cater for different sized pallets 10. However, many of the same segments 30 can be utilised by a multitude of pallets 10 allowing for reduced costs due to economies of scale. The beams 20, segments 30 and braces 70 can be made from different materials to suit specific requirements. For example, in medical environments, the beams 20, segments 30 and braces 70 can all be made of medical grade plastic.

[0051] In this specification, the terms "comprise", "comprises", "comprising" or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.

[0052] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0053] It should be appreciated that various other changes and modifications may be made to the embodiments described without departing from the scope of the invention.

[0054] The disclosure further comprises the following clauses:

CLAUSES:

[0055] 

1. A modular pallet comprising :

at least two spaced apart beams; and

at least two pallet segments;

wherein the beams are located through each of the pallet segments.

2. The modular pallet of clause 1 wherein each beam has a constant cross-sectional along its length.

3. The modular pallet of clause 1 or clause 2 wherein each beam has the same cross-section.

4. The modular pallet of any one of the preceding clauses wherein each beam is an I-beam, H-beam, C-beam or hollow rectangular beam.

5. The modular pallet of any one of the preceding clauses wherein each of the beams is made of the same material.

6. The modular pallet of any one of the preceding clauses wherein the beams are be made from steel, composite fibre, plastic, or fibreglass.

7. The modular pallet of any one of the preceding clauses wherein the beams are parallel to each other.

8. The modular pallet of any one of the preceding clauses wherein at least two of the beams being located adjacent sides of the pallet.

9. The modular pallet of any one of the preceding clauses wherein the beams may be horizontally spaced or vertically spaced.

10. The modular pallet of any one of the preceding clauses wherein the pallet segments are made from plastic.

11. The modular pallet of clause 10 wherein the plastic used is polyethylene or polyurethane.

12. The modular pallet of any one of the preceding clauses wherein one or more segment channels extend through each of the pallet segments.

13. The modular pallet of clause 12 wherein the segment channels extends entirely through or partially through the pallet segments.

14. The modular pallet of any one of the preceding clauses wherein one or more segments are connected to one or more beams.

15. The modular pallet of any one of the preceding clauses wherein the segments include one or more end segments, the one or more end segments being locked to the beams.

16. The modular pallet of any one of the preceding clauses wherein the beam may have a tab that is deformed to lock a segment to the beam.

17. The modular pallet of clause 15 wherein the beam is deformed to lock the end segment to the beam.

18. The modular pallet of any one of the preceding clauses wherein a brace is located between two pallet segments.

19. The modular pallet of clause 18 wherein the brace is in the form of a bracing plate.

20. The modular pallet of any one of the preceding clauses wherein one or more bracing channels extend through each brace, one or more respective beams extending through respective bracing channels.

21. The modular pallet of any one of the preceding clauses wherein each pallet segment includes a deck and a base which are interconnected by two sides.

22. The modular pallet of clause 21 wherein the deck and the base are interconnected by at least one intermediate member.

23. The modular pallet of clause 22 wherein the deck and the base are interconnected by at least two intermediate members.

24. The modular pallet of any one of the preceding clauses wherein at least two apertures are formed within the pallet segment.

25. The modular pallet of any one of the preceding clauses wherein at least three apertures are formed within the pallet segment.

26. The modular pallet of clause 24 or clause 25 wherein all of the apertures are located between the deck and the base.

27. The modular pallet of any one of clauses 21 to 26 wherein one or more C-shaped channels are located within each of the sides.

28. The modular pallet of any one of clauses 23 to 27 wherein one or more C-shaped channels are located through each of the intermediate members.

29. The modular pallet of any one of the preceding clauses wherein there are at least two end segments and two tine segments.

30. The modular pallet of any one of the preceding clauses wherein there are at least two end segments, two tine segments and two infill segments.

31. The modular pallet of any one of the preceding clauses wherein a tine segment is located between an infill segment and an end segment.

32. The modular pallet of clause 31 wherein the end segment has an enclosed front face.

33. The modular pallet of clause 31 or clause 32 wherein the tine segment has tine opening extending between the two sides and bisecting the base.

34. The modular pallet of any one of clauses 18 to 33 wherein a brace is substantially planar in shape and has slightly smaller outer dimensions than the pallets segments.

35. The modular pallet of any one of clauses 18 to 34 wherein the brace is formed from a deck and a base which are interconnected by two sides.

36. The modular pallet of clause 35 wherein the deck and the base of the brace are interconnected by at least one intermediate member.

37. The modular pallet of any one of clauses 18 to 36 wherein at least two apertures are formed within the brace.

38. The modular pallet of any one of clauses 18 to 37 wherein at least three apertures are formed within the brace.

39. The modular pallet of any one of clauses 18 to 36 wherein all of the apertures located through the brace are located between the deck and the base.

40. The modular pallet of any one of clauses 35 to 39 wherein one or more C-shaped channels are located within each of the sides of the brace.

41. The modular pallet of any one of clauses 26 to 40 wherein one or more C-shaped channels are located through each of the intermediate members of the brace.

42. A method of manufacturing a pallet, the method including the steps of:

locating two or more pallet segments over one or more beams

wherein the beams are located through each of the pallet segments

43. The method of clause 42 including the steps of:

locating the pallet segment over one or more beams whilst the pallet segment is at a temperature greater than ambient temperature;

allowing the pallet segment to cool to shrink fit the pallet segment to the one or more beams.

44. The method of clause 42 or 43 wherein the method further includes the step of deforming one or more beams to lock the one or more beams to a pallet segment.

45. The method of any one of clauses 42 to 44 wherein the deformation of the beam occurs at a tab formed within the beam.

46. The method of clause 44 or 45 wherein the deformation of the beam occurs using a tool that applies a force to the beam.

47. The method of clause 46 wherein the tool apply the force to the beam via or through the pallet segment.

48. The method of any one of clauses 42 to 47 wherein the pallet segments are formed from plastic using a forming machine.

49. The method of clause 48 wherein the pallet segments are injection moulded.

50. The method of clause 48 or 49 wherein the pallet segments are located over the beams shortly after being removed from the forming machine.

51. The method of any one of clauses 42 to 50 wherein there are at least two end segments and two tine segments, the tine segments being located between the end segments.

52. The method of any of one of clauses 42 to 51 wherein there are there are at least two end segments, two tine segments and two infill segments wherein a tine segment is located between an infill segment and an end segment.

Claims

1. A modular pallet comprising :

at least two spaced apart beams;

at least two pallet segments; and

at least one brace;

wherein the beams are located through each of the pallet segments and the at least one brace is located between the at least two pallet segments.

2. The modular pallet of any one of the preceding claims wherein the segments include one or more end segments, the one or more end segments being locked to the beams.

3. The modular pallet of any one of the preceding claims wherein the beam may have a tab that is deformed to lock a segment to the beam.

4. The modular pallet of any one of the preceding claims wherein one or more beams are located through the brace.

5. The modular pallet of any one of the preceding claims wherein the brace is in the form of a bracing plate.

6. The modular pallet of any one of the preceding claims wherein one or more bracing channels extend through each brace, one or more respective beams extending through respective bracing channels.

7. The modular pallet of any one of the preceding claims wherein there are at least two end segments and two tine segments.

8. The modular pallet of any one of the preceding claims wherein there are at least two end segments, two tine segments and two infill segments, wherein a tine segment is located between an infill segment and an end segment.

9. The modular pallet of claim 7 or 8 wherein the tine segment has tine opening extending between the two sides and bisecting the base.

10. The modular pallet of any one of the preceding claims wherein the brace is substantially planar in shape and has slightly smaller outer dimensions than the pallets segments.

11. The modular pallet of any one any one of the preceding claims wherein the brace is formed from a deck and a base which are interconnected by two sides.

12. The modular pallet of any one of claims of the preceding claims wherein at least two apertures are formed within the brace.

13. The modular pallet of claim 11 or 12 wherein one or more C-shaped channels are located within each of the sides of the brace.

14. A method of manufacturing a pallet, the method including the steps of:

locating two or more pallet segments over one or more beams;

locating one or more braces between two or more pallet segments;

wherein the beams are located through each of the pallet segments and a brace is located between the at least two pallet segments.

15. The method of claim 14 including the steps of:

locating the pallet segment over one or more beams whilst the pallet segment is at a temperature greater than ambient temperature;

allowing the pallet segment to cool to shrink fit the pallet segment to the one or more beams.

Drawing