WO1998019924A1

WO1998019924A1 - A pallet

Info

Publication number: WO1998019924A1
Application number: PCT/DK1997/000496
Authority: WO
Inventors: Torben Bredal; Erik Sylvest
Original assignee: ALU-PAL APS
Current assignee: ALU-PAL APS
Priority date: 1996-11-01
Filing date: 1997-10-31
Publication date: 1998-05-14
Anticipated expiration: 1999-05-01
Also published as: AU4863097A; EP0935564A1

Abstract

The invention relates to a pallet unit, comprising at least two constituent pallets (1) wherein the at least two constituent pallets are positioned adjacent each other, and are secured in relation to each other, wherein each of these constituent pallets comprises legs in their respective corner areas and wherein rail portions (15) are provided at the outer extremities of the legs, said rail portions (15) extending between the legs in the corner areas of the pallet.

Description

A pallet

The invention relates to a pallet unit for use in the transport, storage and presentation of various goods.

From GB 1 156 430 it is known to connect a number of constituent pallets in order to obtain a larger pallet. This previously known construction uses constituent pallets having separate load bearing surfaces and separate legs. The constituent pallets are secured in relation to each other by means of metal strips fastened to the load bear^¬ ing surfaces of adjacent constituent pallets and further by bolts inserted through holes in the legs of adjacent constituent pallets. Due to the downwardly extending legs, transportation of this pallet on roller conveyors and storing in shelf systems, which is common handling practice, cannot be realised.

US patent No. 1,508,898 discloses a pallet made of a plate which is, at its two opposite sides, folded downwards to form lateral portions with legs. In order to provide a sufficient strength and rigidity of this construction, it is necessary to manufacture the pallet from a plate material of a considerable thickness which influ- ences the weight and also the costs of manufacture as well as the transport.

Additionally, US patent No. 1,741,189 teaches a further, known pallet unit which is, in order to increase the strength and rigidity of the construction, provided with separate support elements arranged between the top portion and each of the lateral portions of the pallet.

From NO 103189, US 37076127, US 4619207 and DE 3217573 a further number of pallets are known. Due to downwardly extending single legs, these pallets cannot be trans- ported on roller conveyor systems and stored in shelf systems.

Various pallets of wood and plastics materials are known. The wooden pallets, e.g. the so-called EUR-pallets and ISO-standardised pallets are heavy and difficult to handle. Due to their downwardly extending single legs, the smaller plastics pallets cannot be transported on roller conveyor systems and be stored in shelf systems. Larger plastics pallets are known which are constructed in a way similar to the above mentioned wooden pallets, i.e. having a load bearing surface, a number of legs extending downwards from this surface and a number of support elements extending between the legs. Similar to the wooden pallets such plastics pallets are heavy and difficult to handle .

It is a common feature of these prior art pallets that they are tailor manufactured especially to fit the de- sired dimensions. Since it is often desirable that pal^¬ lets of different dimensions are available, this means that a correspondingly large number of different moulds must be available for e.g. the plate pallets or the cast pallets. It goes without saying that this involves very elevated production costs. Moreover these known pallet units are not readily suitable for large-size manufacturing since this would require considerable material thickness which influence the material consumption and thus the weight of the final product and its production costs.

It is therefore the object of the present invention to provide a pallet unit which may be manufactured with desired dimensions and at a considerably reduced consumption of material compared to the previous, known pallet units with due regard to the desired strength, with substantially reduced requirements to the production equip- ent and where the end product is able to be transported on roller conveyor systems and is storable in usual shelf systems .

According to the invention this is obtained by a pallet unit, comprising at least to constituent pallets wherein the at least two constituent pallets are positioned adja^¬ cently each other, and are secured in relation to each other, wherein each of these constituent pallets co - prises legs in the corner areas of the pallet being char^¬ acteristic in that rail portions are provided at the outer extremities of the legs, said rail portions extend^¬ ing between the legs in the corner areas of the pallet, preferably along the sides of the pallet.

This pallet unit configuration makes it possible to form pallets with various dimensions by assembling a number of constituent pallets hereby enabling a more flexible and more cost effective manufacturing. Since this pallet unit has rails between legs at two end edges of the finished pallet unit, and optionally in the central region, a sup^¬ port is provided which allows for a considerable reduction of the material thickness in the individual con^¬ stituent pallet and thereby a reduction of the weight. Due to the rail portions beneath the legs of the constituent pallets it is possible to transport such pallet unit along a roller conveyor system, and storage of the pallet unit in a usual shelf system is enabled. The rail portions hereby form structural elements providing both rigidity to the construction as such and a firm connection between the constituent pallets.

In one preferred embodiment of the invention these rail portions comprise means for a releasable connection of the rail portions in relation to the constituent pallets.

This makes it possible to release the individual con- stituent pallet with its load from the pallet unit and hereby allows for a more rational distribution while simultaneously maintaining the flexibility of the smaller constituent pallet at the sales point. In another embodi- ment the rail portions are permanently fastened relative to the legs of the constituent pallets. Hereby the rail portions are conveniently configured to receive the lower end of the legs in a form-close manner. Hereby a connection area without any dead spaces can be obtained between the constituent pallets and the rail portions. Both embodiments provide a high hygienic standard due to at the one side the releasability of the rail portions allowing a proper cleaning and at the other side the form-close connection precluding dead spaces in the connection area.

Preferably the rail portions extend between legs of respective constituent pallets. This adds rigidity to the construction and hereby eliminates the need for further connection between the constituent pallets.

In a preferred embodiment of the invention the rails are configured as to form an extension of the load bearing surface. This allows for adapting the pallet unit to different standard pallet sizes by means of different sized rail portions in combination with constituent pallets of only one size. This allows for a more cost effective manufacturing of the pallet unit.

The invention further relates to a rail device for con- necting constituent pallets to form a pallet unit as defined above in connection with the releasably mounted rail portions. This rail system comprises at least two rail portions each having means for a releasable connection of the respective rail portion in relation to the pallets. These rail portions are conveniently interconnected, preferably by means of flexible belts or the like. Hereby an easier handling of the rail system is ensured. The means for releasably connecting the rail portions in relation to the constituent pallets conveniently comprises elastic belts connected the a rail at one end and having at an opposite end a hook on a similar element for mechanical connection with the constituent pallet. This ensures an easy connection operation for the rail portions. Other releasable fastening means can of course be used.

The invention also relates to a rail device for connecting constituent pallets to form a pallet unit as defined above in connection with the permanently mounted rail portions. This rail device is characteristic in having a contour allowing a form-close contact with the legs of the constituent pallets. This ensures a connection area without any dead spaces, and hereby a high hygienic standard.

The invention further relates to a rail device for con^¬ necting constituent pallets as defined in connection with the pallet unit wherein the width of this is increased by means of the rail device. This rail device comprises a first area adapted for connection in relation to the lower end of the legs of the constituent pallet an upper area adapted for connection in relation to the constituent pallet near the load bearing surface and further comprising a surface which in the mounted state for the aril extends substantially parallel to the pallet unit load bearing surface.

The constituent pallet for construction of a pallet unit as defined in the foregoing is preferably formed by means of a single plate and comprising an upwardly facing, load-bearing surface with four lateral edges that are, in pairs, substantially parallel relative to each other, four legs each of which is provided at a corner of the load-bearing surface and lateral flanges that are substantially perpendicular relative to the load-bearing surface, said lateral flanges extending downwards from each lateral edge and the legs being formed as extensions of said flanges. Such pallet in described more detailed in W09726197.

The constituent pallets can be mutually secured by means of a permanent connection provided at least between a lateral flange on a first of the at least two pallets and an opposite lateral flange on a second one of the at least two pallets, and a further permanent connection may be provided between the at least two constituent pallets at a connecting point which is, relative to a lateral edge, situated a larger distance therefrom than the permanent connection between the two opposite flanges of the at least two constituent pallets, where the further permanent connection is preferably located between opposite legs on respective pallets. The presence of a further connection arranged perpendicularly at a distance from the first connection, a pallet is provided which exhibits a higher degree of tensile strength, which is particularly convenient in case there is no support in the cen- tral region for the pallet as is the case e.g. when lifted by a fork-lift truck. Particularly conveniently the further permanent connection may be provided in the form of a discrete connection at the outer extremity of the legs or it is optionally provided in the form of a continuous connection along edges of opposite legs on respective pallets. The continuous connection provides increased torsional rigidity for the pallet unit. Conveniently, an outer extremity of each leg to be connected to a corresponding leg on an opposite pallet is folded so as to provide a connecting surface which is substantially parallel with the side flanges. According to a convenient embodiment each constituent pallet may be provided with leg edge areas that extend in a plane which is substantially coincident with a plane in which an associated side flange extends. Hereby a permanent connection may also be provided in the region between the side flanges and the outer extremities of the legs.

The pallet unit according to the invention enables the formation of such in e.g. full or semi-pallet format, e.g. in accordance with the EUR or ISO standard pallet format, on the basis of two respective constituent pallets in quarto. The few constituent elements allow for a simple and expedient manufacturing process.

The individual constituent pallets is preferably made of steel or further conveniently of aluminium in order to obtain a weight reduction. Other workable materials, however, may also be useful for this application.

The permanent connection between the constituent pallets and/or between the constituent pallets and the rails may conveniently be established by welding, gluing or rivet^¬ ing, depending on the relevant pallet material.

The invention will now be explained in further detail with reference to the drawings, wherein:

Fig. 1 illustrates a single constituent pallet, seen from above,

Fig. 2 illustrates the constituent pallet shown in

Fig. 1, in a lateral view,

Fig. 3 illustrates the constituent pallet shown in Fig. 1, seen from one end, Fig. 4 illustrates two constituent pallets corresponding to the constituent pallet shown in Fig. 1, which have been joined to form a pallet unit according to the invention,

Fig. 5 is a lateral view of the pallet unit shown in Fig. 4,

Fig. 6 is an end view of the pallet unit shown in Fig. 4,

Fig. 7 is a perspective view of the pallet unit according to the invention shown in Fig. 4,

Fig. 8 illustrates a pallet unit according to the invention comprising four constituent pallets as shown in Fig. 1,

Fig. 9 is a lateral view of the pallet unit shown in Fig. 8,

Fig. 10 is an end view of the pallet unit shown in Fig.

Fig. 11 is a perspective view of the pallet unit shown in Fig. 8,

Fig. 12 illustrates a pallet unit corresponding to the one shown in Fig. 8 where the lower extremities of the legs are provided with rail portions.

Fig. 13 illustrates stacked units of the pallet unit according to the invention shown in Fig. 8, Fig. 14 illustrates the connecting points for the embodiment of the pallet unit shown in Fig. 8, in an enlarged scale,

Figs. 15

A and B illustrate a connecting area around the legs and seen from above and laterally, respectively, and

Figs. 16

A and B illustrate a connecting area around the legs seen from above and laterally, respectively,

Fig. 17 and 18 illustrate a releasable rail system im- mediately before and after connection in relation to a number of constituent pallets,

Fig. 19, 20A and 20B illustrate stacked rail systems of the type shown in figs. 17 and 18,

Fig. 21-23 illustrate a pallet unit comprising a number of constituent pallets and having permanently secured rails,

Fig. 24 illustrate seen from above a rail of the type used in the construction of figs. 21-23, and

Fig. 25 is a cross section of the rail in fig 24 and taken along the line A-A,

Fig. 26, 27 and 28 shows an alternative embodiment of the pallet unit utilising the rails shown in fig.

24 and 25,

Fig. 29 shows a fastening element for releasably fastening of a rail in relation to a pallet, Fig. 30 is a sectional view showing the fastening element of fig. 29 in use,

Fig. 31, 32 and 33 shows in perspective pallet units utilising rails increasing the load bearing surface and

Fig. 34,35 and 36 shows in cross section the connecting areas of the pallets and the rails shown in figs. 31-33.

Figs. 1-3 illustrate that the preferred embodiment of a constituent pallet to form the pallet unit according to the invention comprises a load-bearing, upwardly facing surface 1. The load-bearing surface has four side edges 2,3,4,5 that are mutually parallel in pairs. At respective corners of the load-bearing surface 1, legs 6,7,8,9 are provided that extend downwards and outwards from the load-bearing surface. The lower, free end of each leg forms a support element 10. From each lateral edge 2,3,4,5 a flange 11 extends downwards whereby improved rigidity of the construction is obtained. In the load- bearing surface, depressions 14 are provided. The depres- sion comprises a central, substantially elliptical portion and rectilinear portions that extend from the elliptic portion towards the corners of the load-bearing surface .

The cross-section of the legs is in the form of a double- arch, i.e. in S-shape. In this connection the term 'double-arch' is used to designate that the legs are convex or concave seen from both sides. The legs extend downwards from the load-bearing surface along a curved line. The lateral flanges comprise inwardly folded edge portions that serve to improve manual handling and also serve as support elements when a pallet is lifted and transported by means of a transport device.

Figs. 4-7 show a pallet unit consisting of two constituent pallets that are mutually connected by a permanent connection 12.

Figs. 8-11 show a pallet unit in which two of the pallet units described above, each of which consists of two constituent pallets, are connected to each other by a permanent connection to form a larger pallet unit according to the invention.

From Fig. 12 it will appear that in connection with a pallet unit consisting of four constituent pallets as shown in fig. 8, rail portions 15 are mounted at the outer extremities of the respective legs of the pallets in order to hereby allow the assembled pallet unit to be transported along roller conveyors. Permanent connection of these rail portions allows this connection to form a connection between the constituent pallets which is located a further distance from the lateral edge than the flange connection, and thus, where no direct connection is established between the legs, it may constitute the connection that increases the tensile strength.

It will appear from Fig. 13 how the pallet comprising four constituent pallets may be stacked in such a manner that the height of the stack formed by stacking of a further pallet is increased only with the height of the lateral flange on the pallet and consequently occupies considerably less space than other, known constructions. The stackability presupposes that the legs taper downwards and that any connections between the legs of the respec- tive pallets are provided at the outer edges of these legs.

Fig. 14 illustrates an assembly area at a corner area of four constituent pallets, where a continuous welding seam is provided between each pair of opposite pallets.

Figs. 15A and 15B illustrate an connecting area between two constituent pallets at their legs. Connecting areas 12 are shown between lateral flanges 11, the legs 7,8 and upwardly folded edges 13 of the legs 7,8. Herein, the connecting areas between leg portions are in the form of portions that are planar relative to the lateral flanges 11 in order to allow adhesive connection. Additionally, the upwardly folded outer extremities 13 of the legs are preferably provided with a view to establishing an adhesive connection therebetween on opposite constituent pallets .

Correspondingly, Figs. 16A and 16B illustrate a connecting area where a welding connection is provided. The edge areas of the 7,8 are not necessarily planar for this purpose. Here, the welding connection is established by a number of rectilinear welding seams 12. The presence of the upwardly folded, outer portion 13 of the legs is not necessarily required in this case.

Figs. 17 and 18 show a rail system 16,17,18,19 comprising three mutually connected rail portions immediately before and after positioning of four constituent pallets in these for providing a larger pallet unit, preferably a full-size standard pallet.

The outermost rail portions comprise attachment means in the form of flexible belts 20 connected to the respective rail portion at one end and having at the opposite end hook means 21 for mechanical fastening in relation to each constituent pallet "1. It appears from Fig. 18 that these hook means 21 are connected to the constituent pallets 1 underneath their load-bearing surface (see e.g. fig. 22) . Having secured the constituent pallets in this manner in relation to the rail portions, no further means for mutually fastening or connecting the respective constituent pallets are necessary.

It is possible to place a lift-fork between the constituent pallets 1 and the rail portions to lift the pallet unit, and the rail portions will support the constituent pallet when the pallet unit is placed in a shelf system.

The mutual connection of the rail portions can consist of rigid or flexible elements 19. In case rigid elements are used, the rail system is stacked and stored as shown in Fig. 19. In case flexible elements are used, the respective side rail portions can be inserted into the mid rail portion having approximately the double transverse dimension. This is shown in Fig. 20A, 20B where the flexible element is omitted for the sake of clarity.

A further fastening element 22 for releasably connecting the rails and the constituent pallet is shown in fig. 21. The fastening element 22 comprises a plate element which at a first edge 24 is bend so as to form a hook-like engaging part and at a second edge 23 opposite the first edge 24 is configured with at least two incisions where the edge of the plate 26 between these at least two incisions is bend in one direction so as to form a hook-like engaging part and at an edge portion 25, preferably edge portions 25 at both sides of this engaging portion is bend in the opposite direction so as to form hook-like engaging portions. In fig. 22 the fastening element is shown in engagement with a rail and a constituent pallet at corresponding engagement portions 27-29 in these.

From Fig. 23 and 24 it appears that a rail portion 30 is configured with abutment areas at the respective ends 31,32 and in the mid portion 33, which areas are complementary to the shape of the lower part of the constituent pallets. This allows for a form-close connection in this area, thereby eliminating dead spaces and inherently bac- teria growth. The upper area of the rail is designated 34.

The connection can be effected by welding or gluing in a similar process. The connection of the constituent pal- lets in relation to the rail portions eliminates the need for further means for the mutual connection of the constituent pallets, and the accessibility of the lift-forks is maintained.

A preferred embodiment of the pallet unit shown in fig. 26-28 utilises the same rails 30 as shown in figs. 25-27, where the fastening of these in relation to the constitu^¬ ent pallet is realised by means of straps which are known per se. This makes it possible to release the rails from the pallets, hereby facilitating cleaning and nesting.

Figs. 28-30 shown a further preferred embodiment of the invention where rail portions are permanently attached in relation to the legs of two constituent pallets. From Fig. 21 it appears that four rail portions are used. Fig. 22 is a side view of this, and Fig. 23 is an end view thereof. These four rail portions are identical.

Conveniently the rails 36 connecting the constituent pal- lets 1 increase the width of the pallets load bearing surface as shown in figs. 31-33. By means of such rails it is possible to adapt the dimensions of the pallet unit using constituent pallets of a specific dimension to several standard pallets formats by means of adapting the dimension of the rails load bearing surface increasing part. Apertures 37 are provided in order to allow the engagement of e.g. a fork lift device.

Figs. 34-36 shows partial cross sections of the pallet units shown in figs. 31-33. The rail shown in fig. 34 comprises a friction surface 39 connected to the remaining part 38 of the rail. The rail shown in fig. 35 is a profile having approximately h-shape where the constituent pallet rests on the profile at 39. the rail shown in fig. 36 is a profile of approximately U-shape where the pallet rests on one leg 40 of this and where the other leg 41 at the outer extremity 42 is bend so as to abut the planar vertical side flange 11 of the constituent pallet 1.

The rails shown in figs. 31-36 are preferably permanently fastened in relation to the constituent pallets in order to ensure presence of the required load bearing properties. This is preferably realised by means of welding, gluing, riveting or a similar mechanical fastening.

Claims

C l a i m s

1. A pallet unit, comprising at least two constituent pallets (1) wherein the at least two constituent pallets (1) are positioned adjacently each other, and are secured in relation to each other, wherein each of these constituent pallets comprises legs in their respective cor^¬ ner areas, c h a r a c t e r i z e d in that rail portions (15,16,17,18,30,36) are provided at the outer extremities of the legs, said rail portions extending between the legs in the corner areas of the pallet unit.

2. A pallet unit according to claim 1, c h a r a c t e r i z e d in that these rail portions comprise means (20,21,22) for a releasable connection of the rail portions in relation to the constituent pallets (1).

3. A pallet unit according to claim 1, c h a r a c t e r i z e d in that the rail portions are perma- nently fastened in relation to the legs of the constituent pallets.

4. A pallet unit according to any of the claims 1-3, c h a r a c t e r i z e d in that the rail portions (30) are formed to receive the lower end of the legs in a form-close manner.

5. A pallet unit according to any of the claims 1-4, c h a r a c t e r i z e d in that the rail portions extend between legs of respective constituent pallets.

6. A pallet unit according to any of the claims 1-5, c h a r a c t e r i z e d in that the rails (36) are configured as to form an extension of the load bearing surface.

7. A rail device for connecting constituent pallets to form a pallet unit as ^"defined in claim 1, c h a r a c t e r i z e d in comprising at least two rail portions each having means (16,17) for a releasable con- nection of the respective rail portion in relation to the constituent pallets.

8. A rail device according to claim 7 for connecting constituent pallets c h a r a c t e r i z e d in that the rail portions are interconnected, preferably by means of flexible belts (19) or the like.

9. A rail device according to claim 7 or 8 for connecting constituent pallets, c h a r a c t e r i z e d in that the means for releasably connecting the rail portions in relation to the pallets comprises elastic belts connected to the a rail at one end and having at an opposite end a hook on a similar element for mechanical connection with the constituent pallet (1) .

10. A rail device for connecting constituent pallets to form a pallet unit as defined in claim ^ c h a r a c t e r i z e d in having a contour allowing a form-close contact with the legs of the constituent pal- lets.

11. A constituent pallet for the construction of a pallet unit as defined in claim 1, c h a r a c t e r i z e d in that each of the constituent pallets is formed by means of a single plate and comprising an upwardly facing, load-bearing surface (1) with four lateral edges (2,3,4,5) that are, in pairs, substantially parallel relative to each other, four legs (6,7,8,9) each of which is provided at a corner of the load-bearing surface (1), and lateral flanges (11) that are substantially perpendicular relative to the load-bearing surface, said lateral flanges (11) extending downwards from each lateral edge and the legs being formed as extensions of said flanges .