Nesting of material handling skid in pallet truck

Abstract

The present disclosure relates to a combination of a pallet truck (100) and a skid (200) for transporting cargo from a truck into a building, a method for transporting palletized loads from a truck into a building, and a dual-purpose half-sized pallet (300) transportable by either the pallet truck (100) or the skid (200). The pallet truck (100) is shaped and sized to nest with the skid (200) by including an alignment feature (120, 122, 150, 170) configured to mate the skid (200) with the pallet truck (100). The pallet truck (100) is shaped, sized and structured to lift goods of the skid (200) and at least two palletized loads. The pallet truck (100) is also shaped and sized to fit within the trailer (600) of a truck. The skid (200) includes an alignment feature (260, 270, 500, 540) compatible with the alignment feature (120, 122, 150, 170) of the pallet truck (100), and a lifting mechanism shaped, sized, and configured to lift cargo of the at least one palletized load.

Description

[0001] Related Applications

[0002] Priority is claimed to U.S. Provisional Patent Application No. 63 / 531,933, filed on August 10, 2023, entitled "NESTING OF A MATERIALS-HANDLING SLED IN A PALLET TRUCK," the entire disclosure of which is incorporated herein by reference. Priority is claimed to U.S. Patent Application No. 18 / 368,069, filed on September 14, 2023, entitled "NESTING OF A MATERIALS-HANDLING SLED INA PALLET TRUCK," the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The field of the present disclosure relates generally to material handling vehicles. More specifically, the present disclosure relates to a nested combination of a sled suitable for in-store use and a pallet truck suitable for loading and unloading a delivery truck. Background Art

[0004] A pallet truck is a material handling vehicle capable of supporting and carrying one or more pallets. A typical pallet truck includes a plurality of (generally two) load-lifting forks connected at their heel ends to a chassis or body. The forks generally include one or more load wheels on their bottom sides (generally toward their toe ends). A lifting mechanism, which may be hydraulic or electric, lifts the forks together with the cargo (such as a pallet loaded thereon), and may lift together some or all of the chassis or frame and the forks and the cargo thereon. Generally, the forks and the load thereon are only raised enough to allow the load (e.g., the bottom of a pallet) to be sufficiently clear of the floor to move without dragging on the floor. A steering mechanism, such as a tiller, is generally also provided to steer the pallet truck. Generally, a steerable traction wheel located at the tiller end of the vehicle is connected to the tiller and controlled by the tiller to provide steering capability. A controller for activating the lifting mechanism is generally located on or near the tiller. A pallet truck may provide power to one or more of its wheels to assist in transporting its load, especially when going uphill.

[0005] Pallet trucks are well suited for transporting pallets in warehouses, outdoor yards (assuming the ground is suitably hard and flat) or parking lots, or even in vans or truck beds or trailers. However, pallet trucks are generally not well suited for use in stores. There are several reasons for this. For example, typical pallets are often too wide to fit through store doors or store aisles. In addition, it is difficult to control the pallet via the tiller in a small space. In addition, pallet wheels are known to damage store floors.

[0006] For these reasons, material handling vehicles other than pallet trucks are often used to carry loads (e.g., boxes of beverages, food, or other goods) in stores (such as convenience stores or grocery stores). Conventionally, delivery trucks are parked near the store. After this, the truck driver / operator must transport the goods from the truck to the store. One of the most primitive methods to solve this problem is to use a two-wheeled tilting hand truck or dolly, which can be manually loaded near the delivery truck and then often pushed into the store through the same (one or more) doors used by customers. After arriving at the store, the driver / operator unloads the goods onto the store shelves or in the cold room. This method is inefficient because the load size that the hand truck / dolly can carry is limited; therefore, the store may need to go back and forth to the delivery truck many times to stock up. For the driver / operator, this method is also manually intensive.

[0007] Another approach uses a light duty delivery cart, often referred to as a "sled." A sled has a higher capacity than a hand truck / dolly. However, a sled, like a hand truck / dolly, generally must be loaded manually from a delivery truck outside the store. A typical sled carries the load in a narrower configuration than a pallet truck. For example, a typical load configuration on a sled is the width of one or two cases wide, stacked several high. Compared to a pallet truck, a sled is easier to maneuver in narrow spaces, such as through doorways, hallways, store aisles, and walk-in coolers, and is less likely to damage store floors.

[0008] If the delivery truck or trailer has a lift door, the cart / trolley or skid can enter and exit the truck / trailer bed / van through the lift door and pick up the goods therein. In the case of a skid, the goods are preferably loaded on a smaller pallet, which is about half the size of a conventional square pallet. Such a pallet approximately matches the load area of ​​the skid and is more easily maneuverable through doors, aisles and into the store's coolers.

[0009] Both pallet trucks and skids are used together in limited ways to deliver beverages to stores. For example, one method is to load half-sized pallets into the bed of a truck at a warehouse or distribution center using a standard pallet truck that can carry two half-sized pallets at a time. At the store, the skid is used to remove one or two pallets at a time from the bed of the truck through the truck's lift gate. If necessary, the skid can be used to carry one and a half pallets at a time into the store. Summary of the invention

[0010] The present disclosure generally relates to (1) a pallet truck and skid combination for transporting cargo from a truck into a building, (2) a method for transporting at least one palletized load from a truck into a building, and (3) a dual-purpose pallet that is half the size of a conventional pallet and can be transported by both a pallet truck and a skid.

[0011] In one embodiment, a pallet truck and skid combination can be used to transport cargo from a truck to a building. The combination includes a pallet truck and a skid. The pallet truck is shaped and sized to nest with the skid by including an alignment feature configured to enable the skid to mate with the pallet truck. The pallet truck is shaped, sized, and configured to lift the skid along with at least two palletized loads of cargo. The pallet truck is also shaped and sized to fit within the trailer of a truck. The skid includes an alignment feature compatible with the alignment feature of the pallet truck, and a lifting mechanism shaped, sized, and configured to lift at least one of the palletized loads of cargo.

[0012] Optionally, the pallet truck further includes a first portion of a locking mechanism, and the sled includes a second portion of the locking mechanism. The locking mechanism is shaped and sized to automatically lock the sled to the pallet truck in the nested position when the pallet truck lifts the sled, and to automatically unlock the sled from the pallet truck when the pallet truck lowers the sled, thereby enabling the pallet truck to be moved to unload the sled from the pallet truck. According to one example, the locking mechanism includes a pivot arm on the sled and a hole on the pallet truck, and the pivot arm includes a finger on one end configured to enter the hole when the pallet truck and the sled enter the nested position.

[0013] Optionally, the pallet truck and the sled are electric, and the combination further comprises an inductive charging coil in the pallet truck configured to provide a charge, and an inductive charging coil in the sled positioned and configured to receive a charge from the inductive charging coil in the pallet truck when the sled and the pallet truck are in the nested position.

[0014] In some additional, alternative, or selectively cumulative embodiments, the sled includes two forks, the forks of the sled are configured to be raised and lowered vertically, the sled includes two powered hub wheels, the sled includes a vertical back frame, and / or the sled includes one or more casters that are capable of swiveling in an orientation.

[0015] In another embodiment, a method performs a transfer of at least one palletized load from a truck into a building. The method (1) maneuvers a pallet truck having a nesting skid locked to the pallet truck into a truck bed, (2) picks up at least two palletized loads using the pallet truck having the nesting skid, and maneuvers the at least two palletized loads out of the truck bed to a location proximate an entrance to the building using the pallet truck having the nesting skid; (3) drops the at least two palletized loads using the pallet truck having the nesting skid; (4) automatically unlocks the skid from the pallet truck; (5) detaches the nesting skid from the pallet truck; and (6) picks up at least one palletized load using the skid and maneuvers the at least one palletized load into the building using the skid.

[0016] Optionally, the method further involves unloading at least a portion of the palletized load at one or more target destinations in the building.

[0017] Optionally, the method further involves mechanically raising at least a portion of the palletized load to facilitate said unloading.

[0018] In some additional, alternative, or selectively cumulative embodiments of the method, the pallet truck includes a first portion of a locking mechanism, and the sled includes a second portion of the locking mechanism, and unlocking the sled from the pallet truck includes automatically removing the second portion of the locking mechanism from the first portion of the locking mechanism when the pallet truck lowers the sled.

[0019] According to some embodiments, the building is a convenience store and / or the at least one palletized load comprises beverages.

[0020] In yet another embodiment, a dual-purpose half-size pallet includes a rectangular platform and a plurality of legs. The rectangular platform has a top surface configured to hold and support a plurality of boxes. The rectangular platform also has long sides and short sides. The plurality of legs extend below the top surface. The rectangular platform has a bottom side having a plurality of fork lifting areas, wherein a first pair of fork lifting areas are accessible by forks entering transversely to the long sides, a second pair of fork lifting areas are accessible by forks entering transversely to the long sides, and a third pair of fork lifting areas are accessible by forks entering transversely to the short sides.

[0021] According to some embodiments, the rectangular platform has a thickness, and the first pair of prongs lifting area and the third pair of prongs lifting area are approximately one thickness below the top surface, and the second pair of prongs lifting area is below the top surface by an amount that appreciably exceeds one thickness.

[0022] According to some embodiments, the first pair of fork lift areas are laterally spaced apart by a first distance, the third pair of fork lift areas are laterally spaced apart by the first distance, and the second pair of fork lift areas are laterally spaced apart by a distance greater than the first distance.

[0023] According to some embodiments, the first pair of fork lift area and the third pair of fork lift area are positioned to accommodate pallets being carried by forks of a skid designed for use within a building, and wherein the third pair of fork lift area is positioned to accommodate pallets being carried by a pallet truck designed for use within a warehouse, on a truck, and outside.

[0024] According to some embodiments, the plurality of legs include legs having a U-shape. The legs of the U extend downwardly to ground level, and a base of the U extends partially downwardly to an intermediate level above ground level.

[0025] As will be appreciated by those skilled in the art from this disclosure, certain embodiments of the forklifts and designs disclosed herein can achieve certain advantages, including in some cases one or more of the following: (1) combining the advantages of a pallet truck and a sled; (2) improving the efficiency of delivering goods into a building, such as, for example, delivering beverages to a store; (3) reducing operator strain and physical exertion during the delivery of items into a building; (4) providing a smaller footprint for two material handling vehicles to be stored in the floor space of a single vehicle; (5) enhancing the maneuverability of the sled to better navigate in tight spaces with a small turning radius, particularly in stores, especially those with space constraints such as convenience stores; (6) enabling the sled to turn in a small range, including providing a minimum or near minimum turning radius; and (7) simplifying charging and recharging by facilitating the charging (recharging) of both the sled and the pallet truck via a single outlet and / or a single charger; and (8) providing greater flexibility of use for the pallet, including the ability to be lifted by different machines in different orientations. The foregoing and other advantages of various embodiments will become apparent from the following detailed description of exemplary embodiments with reference to the accompanying drawings, which will be briefly described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is an exploded isometric view of a pallet truck, a mating skid, and two dual-purpose half-size pallets according to one embodiment.

[0027] Figure 2 is an isometric view of a unloading pallet truck and skid in a nested configuration according to one embodiment.

[0028] Figure 3 is in Figure 2 Right side view of the unloading pallet truck and skid in the nested configuration.

[0029] Figure 4 is in Figure 2 Top view of the unloading pallet truck and skid in a nested configuration.

[0030] Figure 5 is in Figure 2Front and side view of the unloading pallet truck and skid in the nested configuration.

[0031] Figure 6 is an isometric view of a pallet truck and skid in a nested configuration with two load pallets according to an embodiment.

[0032] Figure 7 yes Figure 6 Right side view of the pallet truck and skid in a nested configuration with two loaded pallets.

[0033] Figure 8 yes Figure 6 Top view of a pallet truck and skid in a nested configuration with two loaded pallets.

[0034] Fig. 9 Yes Figure 6 Front and side view of a pallet truck and skid in a nested configuration with two loaded pallets.

[0035] Fig.10 is an isometric view of a pallet truck and skid in a nested configuration with one load pallet according to an embodiment.

[0036] Fig.11 is an isometric view of a single unloading pallet truck according to one embodiment.

[0037] Fig.12 yes Fig.11 Right side view of an unloading pallet truck.

[0038] Fig.13 yes Fig.11 Top view of an unloading pallet truck.

[0039] Fig.14 yes Fig.11 Front side view of an unloading pallet truck.

[0040] Fig.15 is an isometric view of a separate unloading skid according to one embodiment.

[0041] Fig.16 yes Fig.15 Right side view of the unloading skid.

[0042] Fig.17 yes Fig.15 Top view of the unloading skid.

[0043] Fig.18 yes Fig.15 Front and side view of the unloading skid.

[0044] Fig.19 yes Fig.15 Rear side view of the unloading skid.

[0045] Fig. 20 is an isometric view of a single skid with a load pallet resting on the ground, according to one embodiment.

[0046] Fig.21 yes Fig.19 Top view of the skid.

[0047] Fig. 22 yes Fig.19 Right side view of the skid.

[0048] Fig.23 yes Fig.19 Top view of the skid.

[0049] Fig.24 yes Fig.19 Front side view of the skid with the load tray in a slightly raised position.

[0050] Fig.25 yes Fig.19 Front side view of the skid with the load tray in a slightly raised position.

[0051] Fig.26 is an isometric view of a single skid with a partially loaded pallet in a raised position according to an embodiment.

[0052] Fig. 27 yes Fig.26 Right side view of the skid.

[0053] Figures 28A-31A is an isometric view of a pallet viewed from various angles according to an embodiment.

[0054] Fig.32A and Fig.33A yes Figures 28A-31A Side view of a tray.

[0055] Fig.34A and Fig.35A They are Figure 28A-Figure 33A Top and bottom views of the tray.

[0056] Figure 28B-Figure 31B is an isometric view of a pallet viewed from various angles according to another embodiment.

[0057] Fig.32B and Fig.33B yes Figure 28B-Figure 31B Side view of a tray.

[0058] Fig.34B and Fig.35B They are Figure 28B-Figure 33B Top and bottom views of the tray.

[0059] Figure 36A-Figure 36D is a bottom view of a pallet truck and a skid at various stages of being nested together according to an embodiment.

[0060] Fig.37A is a side view of a pallet truck and skid showing an internal locking mechanism in an unlocked position according to one embodiment.

[0061] Fig.37B yes Fig.37A Front view of a pallet truck and skids.

[0062] Fig.38A is a side view of a pallet truck and skid showing an internal locking mechanism in a locked position according to one embodiment.

[0063] Fig.38B yes Fig.38A Front view of a pallet truck and skids.

[0064] Fig.39A is a side view of a pallet truck and skid ready to lift a pallet according to one embodiment.

[0065] Fig.39B yes Fig.39A Front view of a pallet truck and skids.

[0066] Fig.40A is a side view of a pallet truck and a skid-lift pallet according to one embodiment.

[0067] Fig.40B yes Fig.40A Front view of a pallet truck and skids.

[0068] Fig.41 is a partial cross-sectional side view of a skid and a pallet truck with a locking device in an unlocked position according to one embodiment.

[0069] Fig.42 is a partial cross-sectional side view of a skid and a pallet truck with a locking device in a locked position according to one embodiment.

[0070] Fig.43 is a bottom perspective view of a partially disassembled skid to illustrate a locking mechanism according to an embodiment.

[0071] Fig.44 is an isometric partial cross-sectional view of a portion of a pallet truck and skid according to an embodiment, showing a locking device in an unlocked position.

[0072] Fig.45 is another isometric partial cross-sectional view of a portion of a pallet truck and skid according to an embodiment, showing the locking device in an unlocked position but on the edge of locking.

[0073] Fig.46 is another isometric partial cross-sectional view of a portion of a pallet truck and skid showing a locking device in a locked position according to an embodiment.

[0074] Figure 47A-47J A sequence showing the transfer of two loaded pallets from a truck into a store using a pallet truck and skids is shown.

[0075] Fig.48 is a flow chart of a method according to one embodiment.

[0076] Fig.49 and Fig.50 is an isometric view of a pallet truck individually engaged in a conventional pallet, according to some embodiments. DETAILED DESCRIPTION

[0077] Basic Description

[0078] Exemplary embodiments are described below with reference to the accompanying drawings. Unless otherwise expressly stated, the size, position, etc. of parts, features, elements, etc. and any distances therebetween are not necessarily to scale and may be out of scale and / or exaggerated for clarity.

[0079] The embodiments described herein are merely examples and are presented by way of illustration and not limitation. Based on the teachings herein, those skilled in the art will recognize that there are alternatives, variations, and equivalents to the exemplary embodiments described herein and their components. For example, other embodiments are possible, variations may be made to the embodiments described herein, and there may be equivalents to the components, parts, or steps that constitute the described embodiments.

[0080] For the sake of clarity and conciseness, certain aspects of components or steps of certain embodiments are presented without excessive details, where such details are obvious to those skilled in the art from the teachings herein and / or where such details would obscure an appreciation of more relevant aspects of the embodiments.

[0081] The terms used herein are only for the purpose of describing specific exemplary embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are also intended to include plural forms, unless the context clearly states otherwise. It should be recognized that the terms "comprise", "comprises", "comprising", "include", "includes", "including", "has", "have" and "having", when used in this document, are open and specify the existence of stated features, parts, steps, operations, elements and / or components, but do not exclude the existence or addition of one or more other features, parts, steps, operations, elements, components, and / or groups thereof. Unless otherwise stated, when narrated, the numerical range includes the upper and lower limits of the range, and any sub-ranges therebetween. Unless otherwise stated, terms such as "first", "second", etc. are only used to distinguish one element from another element, and do not imply any relative order, placement or ranking. For example, one element may be referred to as a "first element," and similarly, another element may be referred to as a "second element," or vice versa. The same is true for labels like (a), (b), (c), or (1), (2), (3), etc. The section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0082] Unless otherwise indicated, the terms "about," "there about," "substantially," and the like mean that quantities, sizes, formulations, parameters, and other quantities and features are not and need not be exact, but may be approximate and / or larger or smaller as desired, reflecting tolerances, conversion factors, rounding, measurement errors, etc., and other factors known to those skilled in the art.

[0083] Spatially relative terms, such as "right," "left," "below," "beneath," "lower," "above," and "upper," etc., may be used herein to facilitate description of the relationship of one element or feature to another element or feature (as shown in the figures). It should be recognized that spatially relative terms are intended to encompass different orientations in addition to the orientations depicted in the accompanying drawings. For example, if the object in the figure is turned over, an element described as being "below" or "beneath" other elements or features will be oriented as being "above" the other elements or features. Thus, the term "below" may, for example, encompass both above and below orientations. The object may be oriented in other ways (e.g., rotated 90 degrees or in other orientations) and the spatially relative descriptions used herein may be interpreted accordingly.

[0084] Unless expressly indicated otherwise, all functional or operational connections may be direct or indirect. Similarly, unless expressly indicated otherwise, all physical connections may be rigid or non-rigid, permanent or temporary, direct or indirect (e.g., via intermediate components).

[0085] Like numbers refer to like elements throughout the text. Thus, the same or similar numbers may be described with reference to other figures even if they are not mentioned or described in the corresponding figure. Furthermore, even elements not labeled by figure numbers may be described with reference to other figures. In addition, the figures may contain non-essential elements that are included only for the sake of thoroughness. If the drawing needs to be changed to improve clarity, these non-essential elements may be deleted entirely or retained in outline form only.

[0086] Not every feature shown in every drawing is labeled with a figure number, even though the same feature may be labeled with a figure number on other drawings. If it is believed that a figure number would unnecessarily clutter the drawing, then the figure number has been omitted. However, all rights are reserved to add figure numbers to the drawings to illustrate various aspects of the embodiments. In addition, some views omit some features shown in other views. Finally, the drawings sometimes show changes from one drawing to another, even though the drawings are intended to depict the same embodiment.

[0087] Overall system

[0088] Figure 11 is an isometric view of a pallet truck 100, a mating skid 200, and two dual-purpose half-size pallets 300 in an aligned but spaced-apart arrangement according to an embodiment. The operating end 205 of the skid 200 is designed to mate with the wall 105 of the body 110 of the pallet truck 100. The forks 210 of the skid 200 are sized and positioned to travel over the forks 115 of the pallet truck 100. The forks 115 include a wide inner support section 120 and a thinner outer section 125. When the skid 200 is fully nested on and against the pallet truck 100, a locking mechanism (an example of which will be described in more detail below) can lock the skid 200 to the pallet truck 100, and the pallet truck 100 lifts the skid 200 off the ground. Figure 1 Also shown are skid plates 170 and 270 , which are examples of alignment features that aid in aligning the skid 200 within the pallet truck 100 , as described in greater detail later herein.

[0089] Figure 1 The pallets 300 shown in the drawings are oriented so that their longitudinal axes 305 are transverse to the forks 115 and 210. This will be referred to herein as the "broadside" orientation of the pallets 300 relative to the pallet truck 100 and / or skid 200. According to this particular illustrated embodiment, in this broadside orientation, the skid 200 and pallet truck 100 can carry two pallets 300. As will be explained later herein, the skid 200 and pallets 300 are also designed so that the skid 200 can carry a single pallet 300 oriented perpendicular to the broadside arrangement, referred to herein as the "inline" orientation.

[0090] Figure 2-Figure 27 The pallet truck 100 and the skid 200 are shown individually or together from different views and perspectives, with and without a load pallet. Figure 2-Figure 5 The pallet truck 100 and skid 200 are shown nested together without any pallets in an isometric view, a right side view (from an operator's vantage point), a top view, and a fork-barring side view, respectively. Figure 6-Figure 9 Respectively similar to Figure 2-Figure 5 , but with two load trays 300 in a sideways orientation. Fig.10 The pallet-truck-sled combinations 100 - 200 are shown in an inline orientation positioned beneath a single pallet 300 . Figure 1-Figure 10 The pallet truck 100 is shown in a lowered position to facilitate sliding beneath the skid 200 . Figure 11-Figure 14 The pallet truck 100 is shown in isolation in an isometric view, a right (side) view, a top view, and a fork-protruding side view, respectively. Figure 15-19 The sled 200 is shown individually in an isometric view, a right side view, a top view, a fork-end side view, and an operator-end side view, respectively. Figure 20-23 Similar to Figure 15-19 , but with one load tray 300 in an in-line orientation. Figure 24-Figure 27 The skids 200 are shown lifting the pallet 300 off the ground to different heights.

[0091] The pallet truck 100 and the skid 200 may be powered by batteries (not shown). Figure 2-Figure 10 In the nested configuration of the pallet truck 100, the sled 200 may optionally be inductively charged by the pallet truck 100. An inductive coil (not shown) behind the sled-facing wall 105 of the body 110 of the pallet truck 100 may be inductively coupled with an inductive coil (not shown) behind a panel in the body of the operating end 205 of the sled 200. The inductive coil in the pallet truck 100 may induce a charge in the inductive coil of the sled 200 to charge the battery in the sled 200. With such inductive charging, the sled 200 may use lower capacity, lighter batteries, which in turn makes the sled 200 lighter, easier to operate, and less likely to damage the store floor. Alternatively, the sled 200 may be charged from the pallet truck 100 using a cable, and pockets or other compartments may be provided on one or more of the pallet truck 100 and the sled 200 to store one or more charging cables when not in use. Whether charging from the pallet truck to the sled is wired or wireless, advantageously only one power outlet and one onboard charger are required to charge both the pallet truck 100 and the sled 200.

[0092] The pallet truck 100, as shown here, includes two pairs of load wheels 130 - two at or near the distal end (top or toe) of each fork 115 - a central steerable wheel 135 at or near the center of the operator (rear end) and two casters 137 on the left and right of the rear end. The casters 137 can enhance the lateral stability of the pallet truck 100, but they can also be omitted. More or fewer load wheels can be included on the forks 115. For example, a single load wheel 130 on each fork 115 may be sufficient; the more distal load wheels 130, when present, can be access rollers. In operation, the load wheels 130 are actuated by known pneumatic, hydraulic, electric or other means to push down against the floor and thereby raise the forks 115 to lift the load off the floor to facilitate movement of the load.

[0093] The center steering wheel 135 is a traction wheel that can be powered to help move the pallet truck 100, particularly when loaded and / or up an incline. The center steering wheel 135 can pivot in response to lateral movement of the tiller 140 to provide steering. The single center steerable wheel 135 can alternatively be a set of two or more wheels.

[0094] The sled 200, as shown here according to this exemplary embodiment, includes two load wheels 230 - one under each fork 210 - and two rear casters 235. The load wheels 230 may include hub motors to help move the sled 200, especially when loaded and / or when going up an incline. That is, the load wheels 230 may be powered to rotate forward and / or backward to move the sled or to help move the sled. The load wheels 230 are preferably wide and / or employ soft rubber tires (solid or pneumatic) to distribute their weight over a larger area, thereby being less likely to damage floors in a store. The two rear casters 235 may alternatively be replaced by a single wheel, but the two-wheel design may better cooperate with the single center steering wheel 135 of the pallet truck 100, depending on the wheel arrangement, and the two wheels reduce the pressure on the ground by two times compared to one wheel of the same size.

[0095] The forks 115 of the pallet truck 100 and the forks 210 and horizontal base legs 260 of the skid 200 and the load wheels 230 thereon are sized, shaped and positioned to fit in a nested configuration, an example of which is as shown in FIG. Figure 1-Figure 10 According to the illustrated embodiment, the fork 115 of the pallet truck fits under the horizontal base leg 260, which is connected to the upright portion of the sled 200 at its proximal end and is located under the fork 210 of the sled 200. In particular, the short inner support section 120 of the fork 115 of the pallet truck 100 fits under the horizontal base leg 260. The sled load wheel 230 may be a motorized hub wheel located at or near the center of the load in the distal direction so as to minimize the turning radius of the sled 200 when the sled 200 turns by pivoting about the midpoint between the two load wheels 230.

[0096] The short inner support sections 120 of the forks 115 of the pallet truck 100 may optionally have an angled or tapered distal end, as shown in the figure, to help align the skid 200 with the pallet truck 100 when they are brought into a nested configuration. Other features may assist in the alignment of the skid 200 and the pallet truck 100, as described in more detail elsewhere in this document. When the casters 235 enter the area between the forks 115, the angled / tapered inner portions of the forks 115 cooperate with the casters 235, the guards, or other features on the skid 200 to align the skid 200 with the pallet truck 100, initially wider apart at the distal end and then closer together at the proximal end. In one embodiment, the guards or other alignment features are spaced apart on the skid 200, and the forks 115 on the pallet truck 100 are spaced apart at the proximal end so that the guards or other features fit closely between the forks 115 at their proximal ends.

[0097] The pallet truck 100 includes a tiller 140 that the operator can use to steer the pallet truck 100. The tiller 140 is linked to the center steerable wheel 135 by known means to control the orientation of the center steerable wheel 135. The tiller 140 may include operator controls in the form of buttons, levers, twist handles, etc. to control features of the pallet truck 100. For example, a throttle control to actuate power rolling may be provided. For example, an emergency brake control may also be provided. As another example, one or more controls may also be provided to actuate the lifting of the forks 115. In addition, controls for pre-programmed fork heights may also be provided, as explained in detail below.

[0098] The pallet truck 100 may optionally include one or more pockets, compartments or slots 180 to store a charging cable. As explained in more detail elsewhere herein, a charging cable or cord may be used to plug into a wall outlet at one end and plug into the pallet truck 100 at the other end to charge the pallet truck 100, while another charging cable or cord may be used to connect between the pallet truck 100 and the sled 200 to charge the sled 200. In this way, both the pallet truck 100 and the sled 200 may be charged using a single wall outlet.

[0099] The sled 200 has a back frame 250 that can help stabilize a load, especially a high load, on the sled fork 210. The operator can use one or more straps (not shown) to secure the load to the back frame 250, if desired.

[0100] Figure 6-Figure 9 The pallet truck 100 and skid 200 are shown nested with two load pallets 300 in an isometric view, a right side view, a top view, and a fork-protruding side view, respectively. Figure 6-Figure 10 Each of the two trays 300 in FIG. 3 is shown as carrying 30 articles 400 stacked in five layers, where each layer is a 2×3 arrangement. Other arrangements of articles on the trays 300 are possible. Each article 400 may be, for example, a case of beverages, food, or other merchandise. Articles 400 may be considered "case equivalents" (substantially equivalent in size, shape, volume, and / or mass), regardless of their actual contents.

[0101] Fig.10A pallet truck 100 and nested skid 200 combination is depicted, positioned to pick up a single pallet 300 in an inline orientation. As shown here, the pallet 300 carries 30 boxes 400 in 5 2x3 layers. As explained in more detail below, the bottom side of the pallet 300 is designed to be carried by the skid 200 (and thus the nested pallet-cart-100-skid-200 combination) in either a sideways or inline orientation and by the pallet truck 100 alone in either orientation. Concomitantly, the forks 115 and 210 are arranged to fit under the pallet 300 and lift the pallet in both a sideways and inline orientation.

[0102] Figure 11-Figure 14 The pallet truck 100 is shown in isolation in an isometric view, a right side view, a top view, and a fork-exposed side view. Fig.11 and Fig.13 100, the fork 115 has a distal section 125 and an inwardly wider section 120 at or near its proximal end (closer to the body / chassis 110). This arrangement of having a wider opening at the distal end of the fork and a narrower opening at the proximal end of the fork can help align the skid 200 in and on the pallet truck 100. As shown in these figures, there is also a taper or slope 122 between the distal section 125 and the inwardly wider section 120. Although the taper 122 is optional, it can also help align the skid 200 in and on the pallet truck 100. Alternatively, there may be no taper 122, in which case each fork 115 will have a Utah shape. Other shapes for the forks 115 are also possible, and the two forks 115 do not have to be symmetrical as shown.

[0103] Notice, Fig.14 The casters 137 are not included to illustrate that they are optional and may be omitted in some designs of the pallet truck 100 .

[0104] Figure 15-19 The skid 200 is shown individually in an isometric view, a right side view, a top view, and a forked side view, respectively. Figure 15-19 Two handles 240 are shown, which can be grasped by the operator's hands to push or pull and steer the sled 200. Casters 235 can pivot to provide steerability in response to lateral forces applied by the operator (preferably via handles 240). The load wheels 230 are attached near the distal ends of horizontal base legs 260, which are connected to the upright portion of the sled 200 at their proximal ends. As shown, when the fork is in the lowered position, the fork 210 rests on or just above the horizontal base legs 260. As shown and described below, the fork 210 (and other components such as the back frame 250) can be raised above the horizontal base legs 260.

[0105] Figure 20-23The skid 200 with a fully loaded pallet 300 is shown in an isometric view, a top view, a right side view and two forked side views, respectively. Figure 20-23 The skid 200 is shown with its forks 210 in an unraised position, such as how the skid 200 may position its forks under the pallet 300 prior to lifting the pallet 300. Fig.24 and Fig.25 The skid 200 is shown with its forks 210 in a raised position so that the pallet 300 is off the ground and ready to be transported by the skid 200 . Fig.24 and Fig.25 They are right side view and fork protrusion side view respectively.

[0106] The vertical range of motion of the forks may be as small as a few (e.g., six) inches to lift the pallet 300 and provide ground clearance for the bottom of the pallet 300. Alternatively, the vertical range of motion of the forks may be quite large, such as, for example, up to 1 foot, 2 feet, or 3 feet, so as to more comfortably load and unload the bottom, bottom second layer, or bottom third layer of the box 400. A controller on or near the handle 240 may be configured to activate a lifting mechanism, which may be pneumatic, hydraulic, electric, or other means. Controls may be provided to enable movement to a limited number of predetermined heights (e.g., off the ground for transport, to load / unload the second layer from the bottom, to load / unload the bottom layer, etc.) or to an operator-selected height. Without such a preset height, it may be difficult for the operator to manually control the height with the desired accuracy. The controller may be a dedicated button, a press-and-hold operation, multiple clicks, etc. The forks 210 and back frame 250 (and possibly other components) may be raised and lowered together.

[0107] Fig.26 and Fig. 27 The skid 200 is shown with a partial load in a raised ergonomic position to facilitate easier loading and unloading of boxes 400 to or from the pallet 300 . Fig.26 is a stereogram, and Fig. 27 It is the right side view.

[0108] Fig.26 and Fig. 27 Also shown is a guard plate 270 below the proximal end of the right horizontal base leg 260. Fig.26 and Fig. 27 200 and the pallet truck 100 are nested together. The guard plate 270 can help align the skid 200 and the pallet truck 100. As shown here, the guard plate 270 includes a small rectangular metal plate oriented vertically and attached to the bottom of the horizontal base leg 260 via an arm. As shown here, the guard plate 270 also preferably includes a skid pad mounted on the outside of the metal plate.

[0109] The pads may be made of any suitable material that can acceptably slide along the inner vertical sides of the forks 115 of the pallet truck 100 to help laterally position the skid 200 for nesting with the pallet truck 100. For example, the pads may be ultra-high molecular weight polyethylene (UHMWPE), which is a plastic with high durability and low friction. As another example, the pads may be a self-lubricating material (e.g., a self-lubricating plastic) or have a low friction coating, such as polytetrafluoroethylene (e.g., ).

[0110] The pads may be removable so that they can be replaced as needed. For example, the metal plate may have one or more threaded horizontal holes, and the sliding pad may have two corresponding recessed holes so that the pads can be removably bolted to the metal plate. Two such holes may be provided. Fig.26 and Fig. 27 shown.

[0111] Fig.26 and Fig. 27 The guard plate 270 shown in FIG. 1 is vertically positioned at the same height as the right fork 115 (specifically, the inner support segment 120) of the pallet truck 100, and is laterally / horizontally positioned close to (and possibly even slightly touching) the inner vertical wall of the right fork 115 (specifically, the inner support segment 120) when the skid 200 and the pallet truck 100 are in proper lateral alignment for nesting. The corresponding guard plate 270 on the left side of the skid 200 (if present) will similarly be vertically positioned at the same height as the left fork 115 (specifically, the inner support segment 120), and is laterally / horizontally positioned close to (and possibly even slightly touching) the inner vertical wall of the left fork 115 (specifically, the inner support segment 120) when the skid 200 and the pallet truck 100 are in proper lateral alignment for nesting.

[0112] Guard 270 comparable Fig.26 and Fig. 27 For example, the guard plate 270 may be approximately the entire length of the inner support segment 120 or a portion thereof. Fig.26 and Fig. 27 One guard plate 270 is shown on the horizontal base leg 260, but multiple guard plates may be placed along the horizontal base leg 260. For example, several guard plates such as guard plate 270 may be placed in alignment along the proximal portion of the horizontal base leg 260, and / or one or more guard plates may be placed along the distal end of the horizontal base leg 260, where the longer outer segments 125 of the forks 115 of the pallet truck 100 are positioned.

[0113] Alternatively or additionally, a guard plate may be mounted along the inner wall of the fork 115 of the pallet truck 100. For example, the guard plate may be placed along the inner side wall of the cone 122 and / or the distal section 125. Such a guard plate may be a strip of durable low friction material attached to the inner side wall, for example, by fasteners (e.g., screws, bolts, rivets), adhesive, or other suitable means. Having a guard plate on the cone 122 and / or the distal section 125 of the fork 115 of the pallet truck 115 may be better than having a guard plate on the skid 200 located outside the horizontal base leg 260 in order to minimize the width of the skid 200.

[0114] The skids described herein are examples of alignment features. Alternatively, other alignment features may be used in place of the guard plates. Other alignment features include, for example, rollers that rotate horizontally around a vertical pin that acts as an axis of rotation. For example, Fig.26 and Fig. 27 The guard plates 270 shown may be replaced by rollers. Another example of an alignment feature is a ball bearing embedded in a partially open cavity along a surface (such as the inside wall of the fork 115 of the pallet truck 100), or in place of the above-mentioned guard pads. In addition, tapered or angled features such as cones 122 are other examples of alignment features. Another example of an alignment feature is a magnet positioned on the pallet truck 100 and / or the skid 200 (particularly the fork 115 and the horizontal base leg 260) to guide them and / or hold them in the proper relative position for nesting. Any feature on the skid 200 or the pallet truck 100 or both that helps to align the pallet truck 100 and the skid 200 in place to nest with each other is an alignment feature.

[0115] Pallet Design

[0116] Figure 28A-Figure 35A are various views of a tray 300 according to one embodiment. Figures 28A-31A It is an isometric view from various top and bottom angles. Fig.32A and Fig.33A The side views are viewed from the long side and the short side respectively. Fig.34A It is a top view. Fig.35A It is the bottom view. Figure 28B-Figure 35B Similar to Figure 28A-Figure 35A , but there are no texture features on the pallet 300 and some features are shown in dashed lines to emphasize their optional nature. The pallet 300 is designed for dual use with both the pallet truck 100 (or similar pallet truck) and the skid 200 (or similar skid). The pallet 300 is also designed to be lifted in either a sideways or in-line orientation relative to a lifting vehicle or its forks. The features that help achieve these design goals will be described next.

[0117] The tray 300 according to this illustrated embodiment has a platform 310 having a top surface 315 and an underside 320. The platform 310 is a table-like surface but has openings or holes where the support legs are located. The top surface 315 has four holes—two U-shaped end holes 330 and two generally rectangular inner holes 340. Below the U-shaped end holes 330 are U-shaped legs 350, and below the inner holes 340 are generally rectangular legs 360.

[0118] The foot 350 is a double-layered U-shaped foot. Along the base of the U is an intermediate foot 370 at a first vertical height. Along each side of the U is a full foot section 380 at a second vertical height, which can be full bottom level or ground level. The intermediate foot 370 can be at a depth of, for example, 20%-50% of the full depth of the second level. The intermediate foot 370 is positioned to mate with the forks 115 of the pallet truck 100 so that the pallet truck 100 can lift the pallet 300 in a sideways orientation by applying the forks 115 to the bottom side of the intermediate foot 370. For example, the center-to-center distance between the intermediate feet 370 is equal to or close to the center-to-center distance between the forks 115 of the pallet truck 100.

[0119] like Fig.35A and Fig.35B As shown, there are fork lift areas 390 and 395 on the bottom side 320 of the platform 310. These areas are where the forks can be installed and lift the pallet 300. The fork lift area 390 between the inner legs 360 and the U-shaped legs 350 is shaped and positioned to match the forks 210 of the skid 200, so that the skid 200 can lift the pallet 300 in a sideways orientation by applying the forks 210 to the areas 390 on the bottom side 320 of the pallet 300. For example, the center-to-center distance between the areas 390 is equal to or approximately the center-to-center distance between the forks 210 of the skid 200. That is, the size of the inner legs 360 is smaller than the gap between the forks 210 on the skid 200 along the length of the pallet 300, and the distance between the middle legs 370 of the U-shaped legs 350 is smaller than the outer lateral extent of the forks 210. Therefore, the space between the center legs 360 and the inner portion of the U-shaped legs 350 is sufficient to install the forks 210.

[0120] In addition, if Fig.35A and Fig.35B As shown, the fork lifting area 395 is shaped and positioned to match the forks 210 of the sled 200 so that the sled 200 can lift the pallet 300 in an inline orientation by applying the forks 210 to the area 395 on the bottom side 320 of the pallet 300, for example, as shown in FIG. Fig.10 and Figure 21-Figure 27 as shown in .

[0121] Additionally, the bottom of the middle leg 370 is also a fork lift area that is shaped and positioned to match the forks 115 of the pallet truck 100 that lifts the pallet 300 in a sideways orientation.

[0122] The dimensions of the tray 300 can be, for example, from about 44 inches to about 49 inches in the long direction, from about 18 inches to about 22 inches wide in the short direction, and from about 7 inches to about 11 inches high in height. The total height of the legs 350 and 360 can be, for example, from about 6 inches to about 8 inches, and the middle legs can be, for example, from about 3.5 inches to about 5.5 inches from the ground. The thickness of the platform 310 can be, for example, from about 2.5 inches to about 3.5 inches. The inner legs 360 can have, for example, a dimension from about 4 inches to about 6 inches multiplied by from about 7 inches to about 11 inches. The middle legs 370 can have, for example, a dimension from about 2.5 inches to about 5 inches multiplied by from about 7 inches to about 11 inches. The full leg section 380 can have, for example, a dimension from about 4 inches to about 6 inches multiplied by from about 3.5 inches to about 5.5 inches. Different versions of the tray 300 can be used. For example, a version for beverages and a version for food may differ in their dimensions for various reasons, such as to better match the load size and / or to better fit in the bed of a truck intended to carry beverages or food, respectively.

[0123] The bottom side of the platform 310 may have an open structure with ribs extending in one or both transverse directions to provide structural strength. For example, longitudinal ribs (in the direction of the longitudinal axis 305) and transverse ribs (perpendicular to the longitudinal axis 305) may form a square honeycomb structure, as shown in Figures 29, 31 and 35. The spacing between the ribs needs to be uneven, as shown in the figure, and need not be the same in the longitudinal and transverse directions. Alternatively, other honeycomb structures such as rectangular, hexagonal or triangular honeycombs may also be used to replace. Alternatively, if necessary, any other suitable structure may be used to enhance the strength and rigidity of the tray 300 to maintain and carry its expected load. Alternatively, the bottom side of the platform 310 may have a closed flat surface, and a honeycomb or other structural strength reinforcement ribs may be present on the inner side between the top surface 315 and the closed flat bottom side surface. Alternatively, the platform 310 may be solid or hollow.

[0124] One or more holes may be provided in the bottom of the feet 350, 360, 370, and / or 380 for draining water, spilled beverages, etc. that would otherwise collect in the foot cavity.

[0125] The legs 350, 360 and 370 may have sloping sidewalls to facilitate stacking of the trays 300 one on top of the other, thereby saving floor space when the trays are not in use. For example, the inner leg 360 may have an inverted truncated pyramid shape as shown, a trapezoidal prism shape, or any other suitable stackable shape. The same is generally true for the U-shaped leg and its components (full leg 380 and intermediate leg 370).

[0126] The top surface 315 may optionally be textured, such as Figure 28A-Figure 35A as shown in, or without, as Figure 28B-Figure 35B The texture of the top surface 315 can reduce the possibility of the box 400 sliding off the top surface 315. Similarly, the bottom of one or more of the legs 350, 360, 370 and / or 380 can also be optionally textured, such as Fig.31A As shown, or not. Texturing the bottom surface of the legs 360 and 380 can reduce the likelihood of the tray 300 accidentally sliding on the floor. Texturing the bottom surface of the middle leg 370 can reduce the likelihood of the tray 300 sliding on the fork 115.

[0127] The legs 350, 360, 370 and / or 380 may optionally have rounded corners, such as Figures 28A-35B shown.

[0128] The tray 300 may be made of any suitable material, such as, for example, plastic (e.g., high density polyethylene (HDPE)). The tray 300 may be manufactured, for example, by injection molding or other known techniques. The tray 300 may be colored and have a unique color. The tray 300 may carry a company name and / or logo and / or text information, such as by molding, printing, applying a sticker, or other means.

[0129] The tray 300 may also have optional notches along the perimeter of the platform 310 for use when wrapping and / or unwrapping the load with plastic wrap (eg, cellophane).

[0130] Nesting and Locking

[0131] Figure 36A-Figure 36D The sequence in which the pallet truck 100 and the skid 200 are brought into a nested relationship is shown. Figure 36A-Figure 36D This is a view from the bottom of the pallet truck 100 and the skid 200. Fig.36A , the proximal (operator) end of the skid 200 has just begun to enter the space between the forks 115 of the pallet truck 100, specifically, the space between the thinner outer sections 125 of the forks 115. Fig.36B , the proximal (operator) end of the sled 200 has passed between the thinner outer sections 125 of the forks 115. Fig.36CIn FIG. 1 , the skid 200 has reached a point where: (1) the guard plates 170 on the pallet truck 100 slip or slide against or near the load wheels 230 on the skid 200, and (2) the guard plates 270 on the skid 200 slip or slide against the inner portion of the wide inner support section 120 of the forks 115 of the pallet truck 100. Thus, the guard plates 170 and 270 help align the skid 200 with the pallet truck 100 for nesting. The guard plates 170 and 270 together prevent angular misalignment of the pallet truck 100 and the skid 200 better than just one set of guard plates alone. In FIG. 1 , the guard plates 170 and 270 on the skid 200 have reached a point where: (1) the guard plates 170 on the pallet truck 100 slip or slide against or near the load wheels 230 on the skid 200, and (2) the guard plates 270 on the skid 200 slip or slide against the inner portion of the wide inner support section 120 of the forks 115 of the pallet truck 100. Thus, the guard plates 170 and 270 help align the skid 200 with the pallet truck 100 for nesting. The guard plates 170 and 270 together prevent angular misalignment of the pallet truck 100 and the skid 200 better than just one set of guard plates alone. Fig.36D , the skid 200 has reached a position where it is completely nested with the pallet truck 100 .

[0132] Figures 37A-40B The pallet truck 100 and skid 200 are shown nested together in various stages of lifting two pallets 300 . Fig.37A and Fig.37B 2 is a right side and front view of the nested pallet truck 100 and skid 200 combination placed under two pallets 300, which are resting on the floor / ground. Fig.37A and Fig.37B As shown, the pallet truck 100 and the skid 200 are not locked to each other because the arm 510 of the locking mechanism 500 has its finger 540 (at Fig.37A (not marked in the figure, but on the left end of arm 510) is in a raised position. Figure 41-46 More information is provided about the locking mechanism 500 . As a result, all wheels of the pallet truck 100 and the skid 200 are on the floor, and the forks 115 of the pallet truck 100 and the forks 210 of the skid 200 are able to move under the pallet 300 without contacting the pallet 300 . Figure 37A-Figure 37B The pallet truck 100 is shown at its base (lowest), unlocked height. There may be a button or other control on the tiller 140 to cause the pallet truck 100 to move to this base, unlocked height. Figure 36A-Figure 36D The sequence occurs at this base, unlocking height.

[0133] Fig.38A and Fig.38B is a right side and front view of a nested and locked pallet truck 100 and skid 200 combination placed under two pallets 300 resting on the floor / ground. Fig.37A and Fig.37B different, Fig.38A and Fig.38B The pallet truck 100 is shown in a raised position such that the pallet truck 100 and the skid 200 are locked together. Fig.38A and Fig.38B The ratio of the fork of the pallet truck 100 to 115 Fig.37A and Fig.37BThe fact that the fork 115 is shown higher in FIG. 1 can be understood from the fact that the most distal wheel 130 below the fork 115 is lowered relative to the fork 115. In fact, lowering the load wheel 130 generally causes the fork 115 to rise. This locking is evident from the fact that the arm 510 of the locking mechanism 500 has its finger 540 (at Fig.38A 5, but on the left end of the arm 510) is in a lowered position so that it engages in the hole 150 of the fork 115 of the pallet truck 100. However, in Fig.38A and Fig.38B In the embodiment, the pallet truck 100 has not yet raised the skid 200 , and all wheels of the pallet truck 100 and the skid 200 remain on the floor, and the forks 115 of the pallet truck 100 and the forks 210 of the skid 200 can still move under the pallet 300 without contacting the pallet 300 . Figure 38A-Figure 38B The pallet truck 100 is shown at its skid locked height. There may be a button or other control on the tiller 140 to cause the forks 115 of the pallet truck 100 to reach this locked height and / or a slightly higher height where the pallet truck raises the skid but is low enough to move the forks under the pallet.

[0134] Fig.39A and Fig.39B 1 is a right side and front side view of a nested and locked pallet truck 100 and skid 200 combination about to lift two pallets 300 from the floor / ground. Fig.39A and Fig.39B Shows that the ratio Fig.38A and Fig.38B Higher position pallet truck 100. Fig.39A and Fig.39B The pallet truck 100 is shown having lifted the skid 200 off the ground. Fig.39A and Fig.39B The ratio of the fork of the pallet truck 100 to 115 Fig.38A and Fig.38B The fact that the pallet truck 100 is shown higher in FIG. 1 can be understood from the fact that the farthest load wheel 130 below the fork 115 is even lowered relative to the fork 115. However, the pallet truck 100 has not yet been lifted. Fig.39A and Fig.39B The tray 300. Figure 39A-Figure 39BThe pallet truck 100 is shown at a pallet engagement height where the top surfaces of the forks 115 of the pallet truck 100 begin to contact the bottom surfaces of the intermediate legs 370 on the bottom side of the pallet 300. At this pallet engagement height, the top surfaces of the forks 210 of the skid 200 have not yet reached the bottom side 320 of the pallet 300 because the pallet truck 100, rather than the skid 200, preferably lifts the pallet when the pallet truck 100 and skid 200 are nested together. There may be a button or other control on the tiller 140 to cause the forks 115 of the pallet truck 100 to reach this pallet engagement height and / or a slightly lower height where the forks can move under the pallet without contacting the pallet.

[0135] Advantageously, there is a button or other control on the tiller 140 to cause the pallet truck 100 to place the forks at an intermediate height between those shown in FIG. 38 and FIG. 39. At such a height, the pallet truck 100 has the lifting skids 200 and they are locked together, but the forks are low enough to fit under the pallet 300. This height is useful before lifting the pallet 300 (to move the forks to a position to lift the pallet 300) and after lowering the pallet (to remove the forks from under the pallet 300). The skids are nested, locked, and lifted off the ground at this height, but the forks are still low enough to fit under the pallet, which may be difficult for the operator to achieve by manually adjusting the fork height over the possible continuous heights. The operator can achieve a preset setting for this height by pressing a button, etc., which can improve the efficiency of the operator.

[0136] Fig.40A and Fig.40B It is a right side and front side view of a nested and locked pallet truck 100 and skid 200 combination about to lift two pallets 300 from the floor / ground. Fig.40A and Fig.40B Shows that the ratio Fig.39A and Fig.39B (and therefore Figure 37A-Figure 38B ) A pallet truck 100 at a higher position. Fig.40A and Fig.40B The pallet truck 100 is shown having lifted both the skid 200 and the pallet 300 off the ground by an amount generally sufficient to move the pallet 300 (and the load thereon). It can be seen that the farthest load wheels 130 below the forks 115 have been lowered further relative to the forks 115, causing the forks 115 to rise. There may be a button or other control on the tiller 140 to cause the forks of the pallet truck 100 to reach this move-ready height.

[0137] Fig.41 and Fig.42 is a side view of the pallet truck 100 and skid 200 in a nested configuration with the unengaged ( Fig.41 ) and join ( Fig.42) is a cutaway window view of one example of a locking mechanism 500 of the embodiment of the present invention. The locking mechanism 500 according to this example is a pivoting arm having a hook or finger on one end that enters a hole when in the locked position. It can be seen that the fork 115 of the pallet truck 100 is Fig.41 In the lowered position so as not to cause the locking mechanism 500 to engage in the locked position, while Fig.42 The middle fork 115 is in a raised position and is high enough to cause the locking mechanism 500 to engage in a locked position. This is just one example of a mechanism for locking the pallet truck 100 and the skid 200 together. Various other mechanisms can achieve the same goal.

[0138] Figure 43-Figure 46 A locking mechanism 500 is further shown. Fig.43 36 is an isometric view of the sled 200 in a partially exploded state from a bottom perspective. As shown in FIG. 36 , the wheels 230 and 235 (and other components) have been removed from the sled 200 to better reveal the locking mechanism 500. Fig.43 As shown, there is a locking mechanism 500 near the proximal end of each horizontal base leg 260, but the locking mechanism 500 can be located anywhere along the length of the horizontal base leg 260, such as, for example, at or near the center of the horizontal base leg 260. The load wheel 230 (not shown in FIG. 36) will be mounted near the opposite, distal end of the horizontal base leg 260. Each locking mechanism 500 has a pivot arm 510 that pivots vertically about a pivot point 520 in the inner portion of the arm 510. The pivot point 520 can be located at or near the middle of the arm 510, or more toward one end or the other. At or near one end of the arm 510, on its bottom side, is an activation area 530. At or near the other end of the arm 510 is a downwardly extending finger 540. As shown here, the pivot point 520 is closer to the activation area and farther away from the finger 540, so that a small movement of the activation area 530 causes a larger movement of the finger 540. As shown here, the pivot point 520 is approximately 75% of the length of the arm 510 from the finger 540 and 25% from the activation area 530. As shown, the activation area 530 is located on the distal end of the arm 510 (i.e., closer to the load wheel 230) and the finger 540 is located on the distal end of the arm 510, but the opposite arrangement is possible. An upward force applied to the activation area 530 causes the arm 510 to vertically pivot about the pivot point 520, so that the activation area 530 is pressed upward and the finger 540 moves downward. As explained with reference to the following figures, the downward movement of the finger 540 causes it to enter the corresponding locking hole 150 on the pallet truck 100 to lock the skid 200 in position on the pallet truck 100.

[0139] As used herein, a locking arrangement means that the pallet truck 100 and the skid 200 cannot move significantly relative to each other. Mechanical tolerances, etc. may result in some small relative movement. For example, the size of the finger 540 and the locking hole 150 may allow for some small relative movement of the two items and, therefore, the two vehicles. Small relative movement is acceptable as long as the movement does not prevent the pallet truck 100 and the skid 200 from moving in tandem when fully loaded. Too much looseness between the pallet truck 100 and the skid 200 may create problems, for example, with respect to the stability of the load.

[0140] Fig.44 is an isometric cross-sectional view of the inside of the right horizontal base leg 260. Fig.44 Portions of the pallet truck 100 are also shown, including locking holes 150 on the top surface of the forks 115 . Fig.44 The locking mechanism 500 is shown in an unlocked position with the finger 540 raised above the locking aperture 150 and the activation area 530 extending downwardly.

[0141] Fig.45 and Fig.46 is an enlarged isometric cross-sectional view of the inside of the right horizontal base leg 260 and through the arm 530. Fig.45 The locking mechanism 500 is shown on the verge of entering the locked position, with the top surface of the prong 115 pushing the activation area 530 upward and the finger 540 about to enter the locking aperture 150 . Fig.46 The locking mechanism 500 is shown in a locked position, with the top surface of the prong 115 pushing the activation area 530 upward and the finger 540 partially entering the locking aperture 150 .

[0142] Locking mechanisms other than pivoting arms are also possible. For example, the fork 115 of the pallet truck 100 may have one or more pivoting claws that grip the sides of the fork 210 or the horizontal base leg 260 or other components of the sled 200 when the fork 115 is raised to contact the corresponding portion of the sled 200. As another example, magnets (e.g., electromagnets) may be placed in the fork 115 of the sled 100 and may also be placed in the fork 210 or the horizontal base leg 260 or other components of the sled 200 so that the magnet attraction locks the sled 200 and the pallet truck 100 together. When the pallet truck 100 initially contacts and lifts the sled 200, a mechanical switch activated by pressure may turn on the magnets to activate the magnetic lock. Other examples are also possible.

[0143] When the sled 200 is unlocked and / or undested from the pallet truck 100, the sled may automatically power on. Likewise, when the sled 200 is locked and / or nested in the pallet truck 100, the sled may automatically shut down. Automatic opening may save time for the operator, and automatic shutoff may save battery power on the sled 200. For example, a magnetic proximity sensor may be used to detect when the sled 200 is in the nested position and used to turn on or off a power circuit for the sled 200. Alternatively, movement of the finger 540 may physically reposition an electrical switch or magnetic sensor or other type of sensor to activate or deactivate power to the sled 200. The sled 200 may have one or more additional indicator lights (e.g., light emitting diodes (LEDs)) to indicate whether the power to the sled 200 is on or off or other modes.

[0144] Use Cases

[0145] Figure 47A-47J 700. A sequence is shown for transporting items (in this case beverages) from the bed 600 of a truck / trailer to the interior of a store 700. First, Figure 47A-47B As shown, the truck / trailer bed 600 is parked near a store 700, such as in a parking lot. Next, the nested and locked combination of the pallet truck 100 and the skid 200 is used in the truck / trailer bed 600 to remove the two fully loaded pallets 300 from the truck / trailer bed 600. In this case, the truck / trailer is equipped with a lift gate 610, through which the load pallet-cart-skid combination 100-200 and its load pallets 300 can be lowered to the ground outside the truck / trailer. At this point, the load pallet-cart-skid combination 100-200 and its load pallets 300 are located in a parking lot outside the store, such as Fig.47C shown.

[0146] After the load pallet-cart-sled combination 100-200 is maneuvered to a temporary storage location, preferably near a store entrance, the load pallet 300 is set on the ground and the pallet-cart-sled combination 100-200 is disengaged and backed away from the load pallet 300, such as Fig.47D Then the skid 200 is unlocked and removed from the pallet truck 100, as shown. Fig.47E As shown. Unlocking can occur automatically when the forks 115 of the pallet truck 100 are fully lowered, thereby disengaging the locking mechanism 500. Once unlocked, the pallet truck 100 can move itself laterally away from the skid 200. The skid 200 can then be used to bring the loaded pallets 300 into the store 700 one at a time. Fig.47F As shown, the skid 200 is guided under one of the trays 300. And, as shown in FIG. Figure 47G As shown, the skid 200 lifts the pallet 300 .

[0147] Next, if Figure 47H As shown, the sled 200 is driven along the ramp 710 into the store 700. The load wheels 230, which are motorized hub wheels, can help move the sled 200 and its load onto the ramp 710. The sled 200 fits through a single door 720 of the store 700. In the store 700, the sled 200 can easily turn 360 degrees, as shown in FIG. Fig.47I As shown, because the caster (a single wheel in this embodiment) can rotate in the direction it is facing, and the load wheel 230 is generally located near the center of the load (from front to back). The skid 200 can then be maneuvered near the store shelf 730 (or other destination) where the load is to be unloaded, such as Fig.47J When approaching the lower layer of the load, the skid 200 can mechanically lift its forks 210 (without human assistance) to easily unload with minimal bending by the operator.

[0148] The empty skid 200 (or carrying an unloaded pallet 300) can then be rolled out of the store 700 and the Figure 47A-47J The process shown in Figure 47G-Figure 47H Another loaded pallet 300 (shown remaining on the ground after the operation) enters the store for unloading onto a shelf 730 or other appropriate destination (e.g., a cooler or storage room).

[0149] Notice, Figure 47A-47J The height of the forks 115 of the pallet truck 100 may be as follows:

[0150] picture high Fig.47A Nested, locked and ready to move under the pallet Fig.47B Lifting / carrying Fig.47C Any / Both of the above Fig.47D Nested, locked and ready to move under the pallet Fig.47E Minimum value (unlocked and not nested) Figures 47F-47J N / A

[0151] Figure 47E-Figure 47J The skid 200 is shown with a single caster 235 (not labeled in FIG. 47 ) laterally centered on the rear side of the skid 200. Other figures depict two casters 235 symmetrically offset from the lateral center. The choice of using one or two (or more) casters 235 on the skid 200 is a design choice.

[0152] Fig.488 is a flow chart of a method 800 for delivering items into a building using a pallet truck 100, a skid 200, and a pallet 300 according to one embodiment. The items are packaged in boxes, and at step 805, the boxes are loaded onto the pallet. The loaded pallet is optionally wrapped with a plastic sheet. Step 805 may occur at, for example, a warehouse, a distribution center, etc. At step 810, the loaded pallet is transported into the bed / truck of a truck / trailer using the pallet-cart-skid nesting combination 100-200. Alternatively, any conventional pallet truck or hydraulic pallet truck (e.g., an end loader) may be used to perform step 810. For efficiency, the loaded pallets may be transported two or more at a time in a sideways orientation into the bed / truck of a truck / trailer. After all the loaded pallets are placed in the bed / truck of the truck / trailer, the pallet-cart-skid nesting combination 100-200 may also be placed in the bed / truck of the truck / trailer.

[0153] At step 815, the truck / trailer is driven to the destination building and, at step 820, parked near the building, which may be, for example, a store, such as a convenience store. At step 825, the two pallets are removed from the truck / trailer using the pallet-cart-skid nesting combination 100-200. Step 825 is preferably performed with the pallets oriented on their side. A lift gate is preferably utilized during step 825. An example of step 825 is shown in FIG. Figure 47A-Figure 47C A typical lift gate can accommodate about four pallets (and pallet-cart-skid combinations) at a time. Therefore, if there are four or more pallets that need to be delivered to the store, the operator can first move two pallets onto the lift gate, then move another two pallets onto the lift gate, and then lower the lift gate with the pallet-cart-skid combination still under the last pair of pallets.

[0154] At step 830, a pair of loaded pallets are placed on the ground near a building, preferably near an entrance to the building (e.g., on a sidewalk or in a parking garage), but in a location that will not disrupt normal activity in and around the building and its entrance. At step 835, the pallet-cart-skid nesting combination 100-200 is removed from the pallets. Examples of steps 825 and 830 are shown in FIG. Figure 47C-Figure 47D Shown in.

[0155] At step 840, the sled 200 is undocked from the pallet truck 100. If the pallet truck 100 and sled 200 are locked together, as is typically the case, then step 840 involves unlocking the sled 200 from the pallet truck 100. The exact unlocking action depends on the design of the locking mechanism. For example, using FIG. Fig.41The locking mechanism 500 shown, step 840 involves disengaging the finger 540 from the hole 150 by lowering the fork of the pallet truck 100. After unlocking, the pallet truck 100 is moved out from under the skid 200. An example of step 840 is shown in FIG. Fig.47E Next, at step 845, the sled 200 is manipulated to pick up one of the load trays in an inline orientation. An example of step 845 is shown in FIG. Figure 47F-47G Shown in.

[0156] At step 850, the pallet is transported into a building using the sled 200 and then to a target destination within the building where the boxes and contents therein will be delivered, per step 855. Step 850 may be assisted by use of a powered hub motor in the load wheels 230 of the sled 200. Due to the narrow size of the sled 200, step 850 may be performed through a single door and a narrow hall or aisle. Due to the high maneuverability of the sled 200, step 850 may be more easily accomplished, particularly through confined spaces, such as are often found within buildings. In order to reduce the physical effort and burden on an operator performing step 855, the sled 200 may mechanically raise its forks (and therefore the boxes thereon) to facilitate easier unloading of the boxes thereon by the operator with no or less vertical bending (e.g., behind the back). An example of step 850 is shown in FIG. Figure 47H-47J Shown in.

[0157] After completing step 855, one pallet has been transferred into the building. Next, at step 860, the skid 200 (now empty, except for the pallet that may be empty or partially empty) is taken outside the building to the place where another pallet unloaded from the truck / trailer's trailer / van is left, and steps 845-855 can be repeated to deliver the goods to the second pallet inside the building. If additional goods are to be transferred in the building, steps 825-855 can be repeated as needed to take the loaded pallets from the truck / trailer's trailer / van and then enter the building one at a time until all the goods have been transferred. If only one pallet needs to be brought into the building, steps 825-855 can be performed with only a single pallet. Alternatively, a single pallet can be transferred from the inside of the truck / trailer's trailer / van all the way into the building using only the skid 200. The empty pallets, which can be stacked to save space, can be returned to a warehouse, distribution center or other source (the same or different location as the one where steps 805-810 are performed). And the pallet truck 100 and the skid 200 can be stored together in a warehouse or the like within the space of one pallet truck and charged together by being plugged into a single power outlet. In other words, the skid 200 does not impose any additional space or power requirements on the warehouse compared to a single pallet truck.

[0158] Fig.49 and Fig.50Another use of the pallet truck 100 is shown. Without the skid 200, the pallet truck 100 can be used to lift and transport any conventional pallet that is compatible with the forks of the pallet truck 100. For example, Fig.49 and Fig.50 A conventional pallet 302 is shown, which may be, for example, a nominal 48" by 40", a North American GMA (Grocery Manufacturers Association) standard size, or any other suitable size and shape. Conventional pallets 302 are often made of wood, but some or all of conventional pallets 302 may also be other materials (e.g., plastic).

[0159] Fig.50 Similar to Fig.49 , but additionally shows (1) an upper backrest frame 160 and (2) an optional slot 180 in which, for example, a charging cable may be stored. The upper backrest frame 160 is mounted on top of the body 110 of the pallet truck 100 and may be used to help stabilize a load on the pallet 302, such as Fig.50 As shown, a pallet 300 or any other load, especially a high load. Fig.50 The upper back frame 160 is shown on a pallet truck 100 with a conventional pallet 302, but the upper back frame may be used with the pallet 300 described above as well. For example, a strap may be placed horizontally around the load and secured to the upper back frame 160 to help stabilize the load. The upper back frame 160 may be permanently attached to the body 110 of the pallet truck 100, or may be removably attached so that it may be attached when needed and removed when not needed. The upper back frame 160 has an opening 165 at or near the center thereof to facilitate access to the skid 200, such as its handle 240, during or after nesting the skid 200 with the pallet truck 100. The upper back frame 160 may have a Fig.50 in different shapes and / or forms, Fig.50 Only one example of a design of upper back frame 160 is shown.

[0160] in conclusion

[0161] The terms and descriptions used above are set forth by way of illustration and example only and are not meant to be limiting. Those skilled in the art will recognize that many variations, enhancements, and modifications of the concepts described herein are possible without departing from the basic principles of the present invention. For example, it will be understood by the skilled person that the subject matter of any sentence, paragraph, or figure may be combined with some or all of the subject matter in other sentences, paragraphs, or figures, unless such combinations are mutually exclusive. The scope of the present invention should therefore be determined only by the claims set forth in subsequent claims, continuation patent applications, or post-publication procedures, and the equivalents of such claims.

Claims

1. A pallet truck (100) and skid (200) combination for transporting cargo from a truck to a building, the combination comprising: A pallet truck (100), wherein the pallet truck (100) is shaped and sized to nest with a skid (200) by including alignment features (120, 122, 150, 170) configured to mate the skid (200) with the pallet truck (100), wherein the pallet truck (100) is shaped, sized and configured to lift the skid (200) along with at least two palletized loads of freight, and wherein the pallet truck (100) is shaped and sized to fit within a trailer (600) of a truck; and A skid (200) comprising: an alignment feature (260, 270, 500, 540) compatible with the alignment feature (120, 122, 150, 170) of a pallet truck (100); and a lifting mechanism shaped, sized and configured to lift at least one palletized load of cargo.

2. The combination of a pallet truck (100) and a skid (200) according to claim 1, wherein: The pallet truck (100) further includes a first portion (150) of a locking mechanism (500), and the skid (200) includes a second portion (510, 520, 530, 540) of the locking mechanism (500); wherein the locking mechanism (500) is shaped and sized to automatically lock the skid (200) to the pallet truck (100) in the nested position when the skid (200) is lifted by the pallet truck (100); and The locking mechanism (500) is shaped and sized to automatically unlock the sled (200) from the pallet truck (100) when the sled (200) is lowered by the pallet truck (100), so that the pallet truck (100) can be moved to detach the sled (200) from the pallet truck (100).

3. The pallet truck (100) and skid (200) combination according to claim 2, wherein: The locking mechanism (500) includes a pivot arm (510) on the sled (200) and a hole (150) on the pallet truck (100), wherein the pivot arm (510) includes, on one end, a finger (540) configured to enter the hole (150) when the pallet truck (100) and the sled (200) enter the nested position (100-200).

4. The pallet truck (100) and skid (200) combination according to any one of claims 1 to 3, wherein: The pallet truck (100) is electric and wherein the skid (200) is electric, the combination further comprising: an inductive charging coil in the pallet truck (100) configured to provide an electrical charge; and An inductive charging coil in the sled (200) is positioned and configured to receive a charge from the inductive charging coil in the pallet truck (100) when the sled (200) and the pallet truck (100) are in the nested position (100-200).

5. The pallet truck (100) and skid (200) combination according to any one of claims 1 to 3, wherein: The sled (200) includes two forks (210).

6. The pallet truck (100) and skid (200) combination according to claim 5, wherein: The fork (210) of the sled (200) is configured to be raised and lowered vertically.

7. The pallet truck (100) and skid (200) combination according to any one of claims 1 to 3, wherein: The skid (200) includes two power hubs (230).

8. The pallet truck (100) and skid (200) combination according to any one of claims 1 to 3, wherein: The skid (200) includes a vertical back frame (250).

9. The pallet truck (100) and skid (200) combination according to any one of claims 1 to 3, wherein: The skid (200) includes casters (235) that are rotatable.

10. A method for intra-building transfer of at least one palletized load from a truck, the method comprising: maneuvering the pallet truck (100) with the nesting skid (200) locked to the pallet truck (100) into the trailer (600) of the truck; Picking up at least two palletized loads using a pallet truck (100) with nesting skids (200), and maneuvering (825) the at least two palletized loads out of a truck bed (600) to a location proximate an entrance to a building using the pallet truck (100) with nesting skids (200); lowering (830) the at least two palletized loads using a pallet truck (100) with nested skids (200); Automatically unlocking the skid (200) from the pallet truck (100); Detaching (840) the nesting skid (200) from the pallet truck (100); and At least one palletized load is picked up (845) using the skid (200) and the at least one palletized load is maneuvered (850) into a building using the skid (200).

11. The method according to claim 10, wherein: The pallet truck (100) includes a first portion (150) of a locking mechanism (500), and the skid (200) includes a second portion (510, 520, 530, 540) of the locking mechanism (500); And wherein unlocking the sled (200) from the pallet truck (100) includes: when the pallet truck (100) lowers the sled (200), the second part (510, 520, 530, 540) of the locking mechanism is automatically removed from the first part (150) of the locking mechanism.

12. The method according to claim 10 or 11, wherein: The building is a convenience store.

13. The method according to claim 10 or 11, wherein: The at least one palletized load includes beverages.

14. The method according to claim 10 or 11, further comprising: At least a portion of the palletized freight is unloaded (855) at one or more target destinations in the building.

15. The method according to claim 14, further comprising: At least a portion of the palletized load is mechanically raised to facilitate said unloading (855).

16. Dual-purpose half-size pallet (300), comprising: a rectangular platform (310) having a top surface (315) configured to hold and support a plurality of boxes (400), the rectangular platform (310) having long sides and short sides; and a plurality of legs (350, 360, 370, 380) extending below the top surface (315), The rectangular platform (310) has a bottom side (320), wherein the bottom side (320) has multiple fork lifting areas (370, 390, 395), wherein a first pair (390) of fork lifting areas (370, 390, 395) can be approached by a fork (210) entering perpendicular to the long side, a second pair (370) of fork lifting areas (370, 390, 395) can be approached by a fork (115) entering perpendicular to the long side, and a third pair (395) of fork lifting areas (370, 390, 395) can be approached by a fork (210) entering perpendicular to the short side.

17. The dual-purpose half-size pallet (300) according to claim 16, wherein: The rectangular platform (310) has a thickness, and the first and third pairs (390, 395) of fork lift areas (370, 390, 395) are approximately one thickness below the top surface (315), and the second pair (370) of fork lift areas (370, 390, 395) are below the top surface (315) by an amount that is noticeably greater than one thickness.

18. The dual-purpose half-size pallet (300) according to claim 16 or 17, wherein: The first pair (390) of fork lift areas (370, 390, 395) are laterally spaced apart by a first distance, the third pair (395) of fork lift areas (370, 390, 395) are laterally spaced apart by the first distance, and the second pair (370) of fork lift areas (370, 390, 395) are spaced apart by a distance greater than the first distance.

19. The dual-purpose half-size pallet (300) according to claim 16 or 17, wherein: The first and third pairs (390, 395) of fork lift areas (370, 390, 395) are positioned to accommodate a pallet (300) being carried by the forks (210) of a skid (200) designed for use within a building, and wherein the second pair (370) of fork lift areas (370, 390, 395) is positioned to accommodate a pallet (300) being carried by a pallet truck (100) designed for use within a warehouse, on a truck, and outside of a building.

20. The dual-purpose half-size pallet (300) according to claim 16 or 17, wherein: The plurality of feet include a foot (350) having a U-shape, a leg (380) of the U-shape extending downward to ground level, and a base (370) of the U-shape extending partially downward to an intermediate level above ground level.

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