Rackable composite shipping pallet for transporting and storing loads

Abstract

A rackable pallet is disclosed that has a load bearing deck, a plurality of cross beams, and a plurality of removable base supports connected approximately perpendicular to the cross beams, and is made of a polymer. One disclosed pallet is open from the bottom and particularly suited for use in large automated warehouses, where machinery lifts and moves pallets by remote control. In one embodiment the pallet comprises a support structure that comprises a plurality of cross beams and a plurality of base supports connected to the cross beams. The deck and the cross beams typically define a single, injection-molded piece of polymer material. The base supports may be removable for repair or replacement. In one embodiment the load bearing deck has a plurality of domes in an array that provide high strength, stiffness, and rigidity.

Description

CROSS-REFERENCE TO RELATED APPLICATION [0001] This is a continuation-in-part of application Ser. No. 10 / 364,867, filed Feb. 10, 2003, entitled LOAD BEARING STRUCTURE FOR SHIPPING PALLET, now U.S. Pat. No. 6,857,377 issued Feb. 22, 2005, which is a continuation-in-part of application Ser. No. 09 / 978,861, filed Oct. 16, 2001 entitled LOAD BEARING STRUCTURE FOR SHIPPING PALLET, both of which are incorporated by reference herein in their entirety.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention generally relates to shipping pallets. More specifically, the invention is directed toward a pallet comprising a load bearing deck and an undercarriage for receiving a forklift, palletjack, hand truck or other automated machinery. [0004] 2. Description of Related Art [0005] Pallets are widely used today to efficiently transport nearly everything worldwide, such as food, beverage, and most every manufactured item or goods. Generally shipping pallets are por...

AI Technical Summary

Benefits of technology

[0011] In one embodiment the rackable pallet for holding and transporting materials comprises a rigid deck that has an upper and a lower surface and a plurality of arch elements configured with their top peaks proximate to the upper surface, the deck including a plurality of adjacent arch elements situated in an intersecting configuration such that downward forces from a load applied to the upper surface of the deck are distributed from the top of the arches downwardly through each of the arch elements and laterally towards adjacent arch elements, such that forces from adjacent arch elements intersect each other to provide lateral compressive forces to strengthen the deck.

[0016] In one embodiment the shipping pallet comprises a load bearing deck that defines an upper surface for receiving the load and a lower surface opposite the upper surface. In this embodiment the load bearing deck comprises a plurality of domes, wherein each dome is defined by an apex located proximate to the upper surface and a plurality of legs extending from the apex and ending at the lower surface. The domes are arranged in an array including a plurality of adjacent domes that provide high strength, stiffness, and rigidity, which makes the pallet suitable for long-term and heavyweight use. In some embodiments the domes have an open structure that reduces material requirements, thereby allowing the pallet to be manufactured at lower weight and lower cost. The pallet may be manufactured of a polymer (e.g., plastics, resin); thus the pallet may be recyclable, ecologically acceptable, and resistant to insect infestation. Additionally, the pallet may be designed in any appropriate manner for four-way entry of a forklift, palletjack, or other automated machinery, making the pallet more versatile than many conventional pallets.

[0021] The deck may comprise structural fill that extends from and between the legs of at least some adjacent domes and provides continuity and additional structure to the load bearing deck. Circular hoops may be provided where the domes end at the lower surface of the load bearing deck. Webbing may be provided between the circular hoops on the lower surface of the deck to provide continuity and structure to the lower surface of the deck.

Problems solved by technology

Conventional shipping pallets are usually constructed of wood or wood products with numerous associated problems.

Wood pallets are heavy, expensive (especially those designed for four-way entry for a forklift) and subject to insect infestation.

Some shipping pallets are constructed from alternative materials, but no matter what construction material is used, conventional shipping pallets suffer from one or more significant problems: limited strength, especially over extended periods of time, cumbersome weight, flexibility and bendability, high expense, limited usability, complex production requirements, ecological unacceptability, and inability to reuse or recycle.

Images