System for palletizing gas cylinders

Abstract

A system for palletizing gas cylinders into one or more gas cylinder layers may include one or more pallet trays. Each pallet tray may have a two-dimensional array of tray-cylinder interface stations. A pallet tray may be in tray supported engagement with a gas cylinder layer disposed downwardly thereof. A pallet tray may be in cylinder supporting engagement with a gas cylinder layer disposed upwardly thereof. The system may include an array cover having a two-dimensional array of cover-cylinder interface stations. The array cover may be in cover supported engagement with a gas cylinder layer disposed downwardly thereof. The array cover and one or more pallet trays may be secured in strapped engagement with one another. A pallet tray may be in pallet supported engagement with a plurality of pallet feet. A plurality of fork relief zones may be defined between adjacently disposed rows and adjacently disposed columns of pallet feet.

Description

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 778,350 filed Mar. 26, 2025, the content of which is incorporated by this reference in its entirety for all purposes as if fully set forth herein.TECHNICAL FIELD

[0002] The disclosure herein relates generally to palletization of gas cylinders for shipment and storage, such as propane cylinders.BACKGROUND

[0003] Conventional systems tend to lack certain features which facilitate space-efficiency, structural integrity, security, and transportability of palletized gas cylinders.SUMMARY

[0004] Exemplary implementations of the system for palletized gas cylinders in accordance with the present disclosure address deficiencies of the conventional art.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Further advantages of the present invention may become apparent to those skilled in the art with the benefit of the following detailed description of the preferred implementations and upon reference to the accompanying drawings in which:

[0006] FIG. 1 is an upper perspective view of an example system for palletized gas cylinders, shown in a fully-assembled configuration;

[0007] FIG. 2 is a lower perspective view of the example system shown in FIG. 1;

[0008] FIG. 3 is a front view of the example system shown in FIG. 1;

[0009] FIG. 4 is a side view of the example system shown in FIG. 1;

[0010] FIG. 5 is a cross-sectional view taken along lines 5-5 in FIG. 4;

[0011] FIG. 6 is a cross-sectional view taken along lines 6-6 in FIG. 4;

[0012] FIG. 7 is a magnified view of detail 7 in FIG. 5;

[0013] FIG. 8 is a magnified view of detail 8 in FIG. 5;

[0014] FIG. 9 is a magnified view of detail 9 in FIG. 5;

[0015] FIG. 10 is a magnified view of detail 10 in FIG. 1;

[0016] FIG. 11 is a magnified view of detail 11 in FIG. 1;

[0017] FIG. 12 is a magnified view of detail 12 in FIG. 2;

[0018] FIG. 13 is a magnified view of detail 10 in FIG. 6;

[0019] FIG. 14 is a magnified view of detail 11 in FIG. 6;

[0020] FIG. 15 is a magnified view of detail 12 in FIG. 6;

[0021] FIG. 16 is an upper perspective view of the example system of FIG. 1, but shown in a partially disassembled configuration and without the securement straps;

[0022] FIG. 17 is a lower perspective view of the example system of FIG. 1, but shown in a partially disassembled configuration and without the securement straps;

[0023] FIG. 18 is a lower perspective view similar to that of FIG. 2, but wherein the pallet feet are shown removed from the lowermost pallet tray;

[0024] FIG. 19 is a side view similar to that of FIG. 3, but wherein the lowermost pallet tray rests directly on the local horizontal surface without pallet feet disposed therebetween;

[0025] FIG. 20 is an upper perspective view of an example pallet tray;

[0026] FIG. 21 is a lower perspective view of the example pallet tray of FIG. 20;

[0027] FIG. 22 is a side view of the example pallet tray of FIG. 20;

[0028] FIG. 23 is a front view of the example pallet tray of FIG. 20;

[0029] FIG. 24 is a top view of the example pallet tray of FIG. 20;

[0030] FIG. 25 is a bottom view of the example pallet tray of FIG. 20;

[0031] FIG. 26 is an upper perspective view of an example array cover;

[0032] FIG. 27 is a lower perspective view of the example array cover of FIG. 26;

[0033] FIG. 28 is a side view of the example array cover of FIG. 26;

[0034] FIG. 29 is a front view of the example array cover of FIG. 26;

[0035] FIG. 30 is a top view of the example array cover of FIG. 26;

[0036] FIG. 31 is a bottom view of the example array cover of FIG. 26;

[0037] FIG. 32 is a magnified view of detail 32 in FIG. 21;

[0038] FIG. 33 is a magnified view of detail 33 in FIG. 21;

[0039] FIG. 34 is a magnified view of detail 34 in FIG. 26;

[0040] FIG. 35 is an upper perspective view of an example pallet foot;

[0041] FIG. 36 is a lower perspective view of the example pallet foot of FIG. 35;

[0042] FIG. 37 is an upper perspective view of an example gas cylinder; and

[0043] FIG. 38 is a lower perspective view of the example gas cylinder of FIG. 37.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] Referring now to the drawings, like reference numerals designate identical or corresponding features throughout the several views.

[0045] With reference to the several drawings, implementations of a system for palletizing gas cylinders into one or more gas cylinder layers are shown generally at 100. The system for palletizing gas cylinders into one or more gas cylinder layers 100 may also be referred to as the system 100.

[0046] Referring to FIGS. 1 and 20-21, particular implementations of a system 100 for palletizing gas cylinders 210 into one or more gas cylinder layers 110 may comprise one or more pallet trays 102. Each said pallet tray 102 may have a tray upper portion 150, a tray lower portion 152, a tray lateral periphery 154, and a two-dimensional array of tray-cylinder interface stations 156.

[0047] Referring to FIGS. 1 and 37-38, in certain implementations of the system 100, each gas cylinder layer 110 may comprise a horizontal two-dimensional array of gas cylinders 210. Each gas cylinder 210 may have an upper dome 214, a lower dome 216, a collar 220 extending upward from the upper dome 214, and a foot ring 218 extending downward from the lower dome 216.

[0048] Referring to FIG. 16, in particular implementations of the system 100, each said pallet tray 102 may be configured to be placed in tray supported engagement with a gas cylinder layer 110 disposed downwardly thereof (e.g., engagement between the pallet tray 102 and the gas cylinder layer 110 wherein the pallet tray 102 is supported by the gas cylinder layer 110). Each said pallet tray 102 may be configured to be placed in cylinder supporting engagement with a gas cylinder layer 110 disposed upwardly thereof (e.g., engagement between the pallet tray 102 and the gas cylinder layer 110 wherein the pallet tray 102 is supporting the gas cylinder layer 110).

[0049] Referring toFIGS. 20-21, in certain implementations of the system 100, each tray-cylinder interface station 156 may include a lower alignment portion 180 disposed along the tray lower portion 152. Each said tray-cylinder interface station 156 may include a foot ring alignment channel 160 disposed along the tray upper portion 150.

[0050] Referring to FIGS. 3, 8, and 20, in particular implementations of the system 100, in the tray supported engagement, each tray-cylinder interface station 156 may be configured to aligningly engage the collar 220 of a respective downwardly disposed gas cylinder 210 by way of the lower alignment portion 180 (e.g., engagement between the collar 220 and the tray-cylinder interface station 156 wherein the collar 180 is aligned by the tray-cylinder interface station 156).

[0051] Referring to FIGS. 3, 8, and 32, in certain implementations of the system 100, in the cylinder supporting engagement, each tray-cylinder interface station 156 may be configured to aligningly receive the foot ring 218 of a respective upwardly disposed gas cylinder 210 by way of the foot ring alignment channel 160 (e.g., the tray-cylinder interface station 156 may receive the foot ring 218 wherein foot ring 218 is aligned by the tray-cylinder interface station 156).

[0052] Referring to FIGS. 3, 8, and 20, in particular implementations of the system 100, each tray-cylinder interface station 156 may include a lower dome engagement portion 158 disposed along the tray upper portion 150. In certain implementations of the system 100, in the cylinder supporting engagement, each tray-cylinder interface station 156 may be configured to supportingly receive the lower dome 216 of a respective upwardly disposed gas cylinder 210 by way of the lower dome engagement portion 158.

[0053] Referring to FIGS. 8 and 37-38, in certain implementations of the system 100, each foot ring 218 may include a lower edge 222. Each collar 220 may include an upper edge 224. In particular implementations of the system 100, for each tray-cylinder interface station 156, the foot ring alignment channel 160 may extend downwardly of the lower alignment portion 180. In certain implementations of the system 100, for a pallet tray 102 in both tray supported engagement and cylinder supporting engagement, at each tray-cylinder interface station 156, the lower edge 222 may extend below the upper edge 224.

[0054] Referring to FIGS. 1, 7, and 26-28, in particular implementations of the system 100, the system 100 may comprise an array cover 104. The array cover 104 may have a cover upper portion 114, a cover lower portion 116, a cover lateral periphery 118, and a two-dimensional array of cover-cylinder interface stations 120. In certain implementations of the system 100, the array cover 104 may be configured to be placed in cover supported engagement with a said gas cylinder layer 110 disposed downwardly thereof (e.g., engagement between the array cover 104 and the gas cylinder layer 110 wherein the array cover 104 is supported by the gas cylinder layer 110). In particular implementations of the system 100, each said cover-cylinder interface station 120 may include a collar receiving portion 124. In certain implementations of the system 100, in the cover supported engagement, each said cover-cylinder interface station 120 may be configured to aligningly receive the collar 220 of a respective downwardly disposed gas cylinder 210 by way of the collar receiving portion 124.

[0055] In certain implementations of the system 100, each said cover-cylinder interface station 120 may include an upper dome engagement portion 122 disposed along the cover lower portion 116. In particular implementations of the system 100, in the cover supported engagement, each said cover-cylinder interface station 120 may be configured to engage the upper dome 214 of a respective downwardly disposed said gas cylinder 210 by way of the upper dome engagement portion 122.

[0056] In particular implementations of the system 100, each said collar receiving portion 124 may include a collar aperture 132 extending therethrough. In certain implementations of the system 100, the collar aperture 132 may be configured for a said collar 220 to extend through the collar aperture 132 in the cover supported engagement.

[0057] Referring to FIGS. 26-27, in certain implementations of the system 100, the array cover 104 may include a plurality of cover stiffener segments 146. Each said cover stiffener segment 146 may define a cover stiffener channel 148. In particular implementations of the system 100, each said cover stiffener segment 146 may extend between a pair of said cover-cylinder interface stations 120.

[0058] In particular implementations of the system 100, the array cover 104 may include a plurality of cover stiffener ribs 144. In certain implementations of the system 100, at least a subset of the cover stiffener ribs 144 may each extend between a pair of said cover stiffener segments 146 extending in parallel with one another.

[0059] Referring to FIG. 26, in certain implementations of the system 100, the array cover 104 may include a plurality of cover strap interface portions 128 disposed along the cover lateral periphery 118. Referring to FIG. 20, in particular implementations of the system 100, each said pallet tray 102 may include a plurality of tray strap interface portions 164 disposed along the tray lateral periphery 154. Referring to FIGS. 10-12, in certain implementations of the system 100, the array cover 104 and the one or more pallet trays 102 may be configured to be secured in strapped engagement with one another by way of the cover strap interface portions 128 and the tray strap interface portions 164.

[0060] Referring to FIGS. 13-15, in particular implementations of the system 100, each said tray strap interface portion 164 may include a tray strap detent 166 configured to restrict lateral movement of a securement strap 108 relative to the tray strap interface portion 164 in the strapped engagement. In certain implementations of the system 100, each said cover strap interface portion 128 may include a cover strap detent 130 configured to restrict lateral movement of a securement strap 108 relative to the cover strap interface portion 128 in the strapped engagement.

[0061] In certain implementations of the system 100, each said tray strap interface portion 164 may include a tray strap aperture 168 extending therethrough. The tray strap aperture 168 may be configured for a securement strap 108 to extend through the tray strap aperture 168 in the strapped engagement. In particular implementations of the system 100, each said cover strap interface portion 128 may include a cover strap aperture 132 extending therethrough. The cover strap aperture 132 may be configured for a securement strap 108 to extend through the cover strap aperture 132 in the strapped engagement.

[0062] In particular implementations of the system 100, each said tray strap interface portion 164 may include a tray strap aperture sleeve 170 disposed inboard of the tray lateral periphery 154. Each said tray strap aperture sleeve 170 may define an outer periphery of a corresponding said tray strap aperture 168. In certain implementations of the system 100, each said cover strap interface portion 128 may include a cover strap aperture sleeve 134 disposed inboard of the cover lateral periphery 118. Each said cover strap aperture sleeve 134 may define an outer periphery of a corresponding said cover strap aperture 132.

[0063] Referring to FIG. 21, in certain implementations of the system 100, the tray lateral periphery 154 may include a tray peripheral wall 162 having a tray strap relief 172 at each tray strap interface portion 164. Each said tray strap relief 172 may be configured to engage an outer segment 204 of a securement strap 108 in the strapped engagement. Referring to FIGS. 11-12 and 14-15, in particular implementations of the system 100, each said tray strap aperture 168 may be disposed inboard of a respective said tray strap relief 172. The tray strap aperture 168 may be configured to receive a corresponding inboard segment 202 of a securement strap 108 in the strapped engagement.

[0064] Referring to FIG. 26, in particular implementations of the system 100, the cover lateral periphery 118 may include a cover peripheral wall 126 having a cover strap relief 136 at each cover strap interface portion 128. Each said cover strap relief 136 may be configured to engage an outer segment 204 of a securement strap 108 in the strapped engagement. Referring to FIGS. 10 and 13, in certain implementations of the system 100, each said cover strap aperture 132 may be disposed inboard of a respective said cover strap relief 136. The cover strap aperture 132 may be configured to receive a corresponding inboard segment 202 of a securement strap 108 in the strapped engagement.

[0065] In certain implementations of the system 100, the one or more pallet trays 102 and the array cover 104 may each be comprised of injection-molded polymer.

[0066] Referring to FIGS. 9, 16, and 35-36, particular implementations of the system 100 may comprise a plurality of pallet feet 106. Each said pallet foot 106 may have an outer wall 190, a base portion 192 for engaging a local horizontal surface 228, and a pallet foot upper edge 194. In certain implementations of the system 100, each said pallet tray 102 may be configured to be placed in pallet supported engagement with the plurality of pallet feet 106 (e.g., engagement between the pallet tray 102 and the plurality of pallet feet 106 wherein the pallet tray 102 is supported by the plurality of pallet feet 106). In particular implementations of the system 100, in the pallet supported engagement, each said tray-cylinder interface station 156 may be configured to aligningly engage the pallet foot upper edge 194 of a respective said pallet foot 106 by way of the lower alignment portion 180.

[0067] Referring to FIGS. 32 and 35-36, in certain implementations of the system 100, each said pallet foot 106 may include one or more pallet foot securement members 198. In particular implementations of the system 100, each said lower alignment portion 180 may include one or more pallet foot retention apertures 182 extending therethrough. In certain implementations of the system 100, each said pallet foot 106 may be configured to be secured to a respective said lower alignment portion 180 by way of secured engagement between respective said pallet foot securement members 198 and corresponding said pallet foot retention apertures 182. In particular implementations of the system 100, each of the one or more pallet foot securement members 198 may comprise cantilever snaps.

[0068] Referring to FIGS. 2-4, certain implementations of the system 100 may comprise a two-dimensional array of said pallet feet 106. In particular implementations of the system 100, in the pallet supported engagement, a plurality of fork relief zones 112 may each be defined between adjacently disposed columns of the two-dimensional array of said pallet feet 106. In certain implementations of the system 100, in the pallet supported engagement, a plurality of fork relief zones 112 may each be defined between adjacently disposed rows of the two-dimensional array of said pallet feet 106. In particular implementations of the system 100, the fork relief zones 112 may each be configured to receive a fork of a forklift.

[0069] Referring to FIGS. 20-21, in particular implementations of the system 100, each said pallet tray 102 may include a plurality of tray stiffener segments 186. Each said tray stiffener segment 186 may define a tray stiffener channel 188. In certain implementations of the system 100, each said tray stiffener segment 186 may extend between a pair of said tray-cylinder interface stations 156. In certain implementations of the system 100, each said pallet tray 102 may include a plurality of tray stiffener ribs 184. In particular implementations of the system 100, at least a subset of the tray stiffener ribs 184 may each extend between a pair of said tray stiffener segments 186 extending in parallel with one another.

[0070] Referring to FIGS. 1, 16, and 20-21, a system 100 for palletizing gas cylinders 210 into one or more gas cylinder layers 110 may comprise a plurality of pallet trays 102. The plurality of pallet trays 102 may include a lowermost pallet tray 102a and an uppermost pallet tray 102b. Each said pallet tray 102 may have a tray upper portion 150, a tray lower portion 152, a tray lateral periphery 154, and a two-dimensional array of tray-cylinder interface stations 156.

[0071] Certain implementations of the system 100 may comprise a plurality of gas cylinder layers 110. The plurality of gas cylinder layers 110 may include an uppermost gas cylinder layer 110b and a lowermost gas cylinder layer 110a. Each said gas cylinder layer 110 may comprise a horizontal two-dimensional array of gas cylinders 210.

[0072] Referring to FIGS. 26-28, particular implementations of the system 100 may comprise an array cover 104. The array cover 104 may have a cover upper portion 114, a cover lower portion 116, a cover lateral periphery 118, and a two-dimensional array of cover-cylinder interface stations 120.

[0073] Referring to FIG. 16, in certain implementations of the system 100, by way of the tray-cylinder interface stations 156, each said tray upper portion 150 may be configured for cylinder supporting engagement with any one of the gas cylinder layers 110. By way of the tray-cylinder interface stations 156, each said tray lower portion 152 may be configured for tray supported engagement with any one of the gas cylinder layers 110.

[0074] Referring to FIGS. 2 and 16, in particular implementations of the system 100, by way of the cover-cylinder interface stations 120, the cover lower portion 116 may be configured for cover supported engagement with any one of the gas cylinder layers 110.

[0075] Referring to FIGS. 3-4 and 19, in certain implementations of the system 100, for the lowermost pallet tray 102a, the tray lower portion 152 may be configured for resting engagement with a local horizontal surface 228. The tray upper portion 150 may be in cylinder supporting engagement with the lowermost gas cylinder layer 110a.

[0076] In particular implementations of the system 100, for the uppermost pallet tray 102b, the tray lower portion 152 may be in tray supported engagement with one of the gas cylinder layers 110. The tray upper portion 150 may be in cylinder supporting engagement with the uppermost gas cylinder layer 110b.

[0077] In certain implementations of the system 100, the cover lower portion 116 of the array cover 104 may be in cover supported engagement with the uppermost gas cylinder layer 110b.

[0078] In certain implementations of the system 100, the plurality of pallet trays 102 may include one or more intermediate pallet trays disposed between the lowermost pallet tray 102a and the uppermost pallet tray 102b. In particular implementations of the system 100, the plurality of gas cylinder layers 110 may include one or more intermediate gas cylinder layers disposed between the lowermost gas cylinder layer 110a and the uppermost gas cylinder layer 110b.

[0079] Referring to FIGS. 37-38, in particular implementations of the system 100, each said gas cylinder 210 may have an upper dome 214, a lower dome 216, a collar 220 extending upward from the upper dome 214, and a foot ring 218 extending downward from the lower dome 216. Referring to FIGS. 20-21, in certain implementations of the system 100, each said tray-cylinder interface station 156 may include a lower alignment portion 180 disposed along the tray lower portion 152. Each said tray-cylinder interface station 156 may include a foot ring alignment channel 160 disposed along the tray upper portion 150. Referring to FIGS. 26-28, in particular implementations of the system 100, each said cover-cylinder interface station 120 may include a collar receiving portion 124. Referring to FIGS. 3, 8, and 20, In certain implementations of the system 100, in the tray supported engagement, a respective said tray-cylinder interface station 156 may be aligningly engaged with the collar 220 of a respective downwardly disposed said gas cylinder 210 by way of the lower alignment portion 180. Referring to FIGS. 3, 8, and 32, in particular implementations of the system 100, in the cylinder supporting engagement, a respective said tray-cylinder interface station 156 may aligningly receive the foot ring 218 of a respective upwardly disposed said gas cylinder 210 by way of the foot ring alignment channel 160. Referring to FIGS. 1, 7, and 26-28, in certain implementations of the system 100, in the cover supported engagement, a respective said cover-cylinder interface station 120 may aligningly receive the collar 220 of a respective downwardly disposed said gas cylinder 210 by way of the collar receiving portion 124.

[0080] Referring to FIGS. 8 and 37-38, in certain implementations of the system 100, each said foot ring 218 may include a lower edge 222. Each said collar 220 may include an upper edge 224. In particular implementations of the system 100, for each said tray-cylinder interface station 156, the foot ring alignment channel 160 may extend downwardly of the lower alignment portion 180. In certain implementations of the system 100, for a said pallet tray 102 in both tray supported engagement and cylinder supporting engagement, at each said tray-cylinder interface station 156, the lower edge 222 may extend below the upper edge 224.

[0081] Referring to FIGS. 10-12, 20, and 26, in particular implementations of the system 100, the array cover 104 may include a plurality of cover strap interface portions 128 disposed along the cover lateral periphery 118. In certain implementations of the system 100, each said pallet tray 102 may include a plurality of tray strap interface portions 164 disposed along the tray lateral periphery 154. In particular implementations of the system 100, the array cover 104 and the pallet trays 102 may be secured in strapped engagement with one another by way of the cover strap interface portions 128 and the tray strap interface portions 164.

[0082] Referring to FIGS. 9, 16, and 35-36, in certain implementations of the system 100, the system 100 may comprise a two-dimensional array of pallet feet 106. Each said pallet foot 106 may have an outer wall 190, a base portion 192 for engaging a local horizontal surface 228, and a pallet foot upper edge 194. In particular implementations of the system 100, the lowermost pallet tray 102a may be in pallet supported engagement with the pallet feet 106. In certain implementations of the system 100, in the pallet supported engagement, each respective said tray-cylinder interface station 156 may be aligningly engaged with the pallet foot upper edge 194 of a corresponding said pallet foot 106 by way of the lower alignment portion 180.

[0083] Referring to FIGS. 2-4, in particular implementations of the system 100, a plurality of fork relief zones 112 may each be defined between adjacently disposed columns of the two-dimensional array of said pallet feet 106. In certain implementations of the system 100, a plurality of fork relief zones 112 may each be defined between adjacently disposed rows of the two-dimensional array of said pallet feet 106. In particular implementations of the system 100, the fork relief zones 112 may each be configured to receive a fork of a forklift.

[0084] Anywhere a letter is used in conjunction with a reference number in the present specification and drawings, it is intended to identify a specific instance of the general case. For example, a pallet tray is shown generally at 102 and specific instances of the pallet tray 102 may be denoted at 102a-102d. In certain implementations of the system 100, each of these instances may be structurally identical to one another while in other implementations the feature sets may differ from one another.

[0085] Within this disclosure, different entities (which may variously be referred to as “elements,”“members,”“assemblies,” other components, etc.) may be described or claimed as “configured” to perform one or more tasks or operations. This formulation [entity] configured to [perform one or more tasks]—is used herein to refer to structure (i.e., something physical, such as a detent). More specifically, this formulation is used to indicate that this structure is arranged to perform the one or more tasks during operation. A structure can be said to be “configured to” perform some task even if the structure is not currently being operated. A “thrust bearing configured to facilitate an axial force transfer” is intended to cover, for example, a thrust bearing that has force transfer members which facilitate this axial force transfer during operation, even if the bearing in question is not currently being used (e.g., no load is currently being applied). Thus, an entity described or recited as “configured to” perform some task refers to something physical, such as a device, circuit, memory storing program instructions executable to implement the task, etc. This phrase is not used herein to refer to something intangible.

[0086] The term “configured to” is not intended to mean “configurable to.” An unprogrammed FPGA, for example, would not be considered to be “configured to” perform some specific function, although it may be “configurable to” perform that function and may be “configured to” perform the function after programming.

[0087] The following listing matches certain terminology used within this disclosure with corresponding reference numbers used in the non-limiting implementations illustrated in the several figures.

[0088] 100 system (i.e., system for palletizing gas cylinders, i.e., system for palletizing gas cylinders into one or more gas cylinder layers)

[0089] 102 pallet tray (e.g. lowermost or intermediately disposed; e.g. comprised of molded polymer)

[0090] 102a lowermost pallet tray

[0091] 102b uppermost pallet tray

[0092] 102c first intermediate pallet tray

[0093] 102d second intermediate pallet tray

[0094] 104 array cover (e.g. comprised of molded polymer)

[0095] 106 pallet foot

[0096] 108 securement strap (e.g., comprising polypropylene, polyester, steel or textile)

[0097] 110 gas cylinder layer

[0098] 110a lowermost gas cylinder layer

[0099] 110b uppermost gas cylinder layer

[0100] 110c first intermediate gas cylinder layer

[0101] 110d second intermediate gas cylinder layer

[0102] 112 fork relief zone (configured to receive a fork of a forklift)

[0103] 114 cover upper portion

[0104] 116 cover lower portion

[0105] 118 cover lateral periphery

[0106] 120 cover-cylinder interface station

[0107] 122 upper dome engagement portion (e.g. for receiving the upper dome of a gas cylinder)

[0108] 124 collar receiving portion (e.g. collar aperture; for receiving the collar of a gas cylinder)

[0109] 126 cover peripheral wall

[0110] 128 cover strap interface portion (of array cover)

[0111] 130 cover strap detent

[0112] 132 cover strap aperture

[0113] 134 cover strap aperture sleeve

[0114] 136 cover strap relief

[0115] 138 cover laterally outboard face (of cover peripheral wall)

[0116] 140 cover peripheral wall terminal edge (e.g., upwardly oriented)

[0117] 142 cover drain aperture

[0118] 144 cover stiffener rib

[0119] 146 cover stiffener segment

[0120] 148 cover stiffener channel

[0121] 150 tray upper portion

[0122] 152 tray lower portion

[0123] 154 tray lateral periphery

[0124] 156 tray-cylinder interface station

[0125] 158 lower dome engagement portion (e.g. for receiving the lower dome of a gas cylinder)

[0126] 160 foot ring alignment channel (e.g., for aligningly receiving the foot ring of a gas cylinder)

[0127] 162 tray peripheral wall

[0128] 164 tray strap interface portion (of pallet tray)

[0129] 166 tray strap detent

[0130] 168 tray strap aperture

[0131] 170 tray strap aperture sleeve

[0132] 172 tray strap relief

[0133] 174 tray laterally outboard face (of tray peripheral wall)

[0134] 176 tray peripheral wall terminal edge (e.g., downwardly oriented)

[0135] 178 tray drain aperture 180 lower alignment portion (e.g., for aligningly engaging a pallet foot or tank collar)

[0136] 182 pallet foot retention aperture (e.g., to receive a pallet foot securement member)

[0137] 184 tray stiffener rib

[0138] 186 tray stiffener segment

[0139] 188 tray stiffener channel

[0140] 190 outer wall (of pallet foot)

[0141] 192 base portion (of pallet foot; e.g., to engage local horizontal surface)

[0142] 194 pallet foot upper edge (of outer wall)

[0143] 196 pallet foot internal compartment

[0144] 198 pallet foot securement member (e.g., cantilever snap)

[0145] 200 pallet foot rib (e.g., stiffener rib extending within the pallet foot internal compartment)

[0146] 202 strap inboard segment

[0147] 204 strap outboard segment

[0148] 206 strap upper end

[0149] 208 strap lower end

[0150] 210 gas cylinder (e.g., propane cylinder)

[0151] 212 barrel (of gas cylinder)

[0152] 214 upper dome (of gas cylinder)

[0153] 216 lower dome (of gas cylinder)

[0154] 218 foot ring (of gas cylinder)

[0155] 220 collar (of gas cylinder)

[0156] 222 lower edge (of foot ring)

[0157] 224 upper edge (of collar)

[0158] 226 handle (of collar)

[0159] 228 local horizontal surface (e.g., ground or floor)

[0160] 230 upward direction

[0161] 232 downward direction

[0162] While implementations of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims

1. A system for palletizing gas cylinders into one or more gas cylinder layers, the system comprising:one or more pallet trays, each said pallet tray having a tray upper portion, a tray lower portion, a tray lateral periphery, and a two-dimensional array of tray-cylinder interface stations;wherein(a) each said gas cylinder layer comprises a horizontal two-dimensional array of gas cylinders, each said gas cylinder having an upper dome, a lower dome, a collar extending upward from the upper dome, and a foot ring extending downward from the lower dome;(b) each said pallet tray is configured to be placed in(i) tray supported engagement with a said gas cylinder layer disposed downwardly thereof; and(ii) cylinder supporting engagement with a said gas cylinder layer disposed upwardly thereof;(c) each said tray-cylinder interface station includes a lower alignment portion disposed along the tray lower portion and a foot ring alignment channel disposed along the tray upper portion;(d) in the tray supported engagement, each said tray-cylinder interface station is configured to aligningly engage the collar of a respective downwardly disposed said gas cylinder by way of the lower alignment portion; and(e) in the cylinder supporting engagement, each said tray-cylinder interface station is configured to aligningly receive the foot ring of a respective upwardly disposed said gas cylinder by way of the foot ring alignment channel.

2. The system of claim 1, wherein(a) each said tray-cylinder interface station includes a lower dome engagement portion disposed along the tray upper portion; and(b) in the cylinder supporting engagement, each said tray-cylinder interface station is configured to supportingly receive the lower dome of a respective upwardly disposed said gas cylinder by way of the lower dome engagement portion.

3. The system of claim 1, wherein(a) each said foot ring includes a lower edge and each said collar includes an upper edge;(b) for each said tray-cylinder interface station, the foot ring alignment channel extends downwardly of the lower alignment portion; and(c) for a said pallet tray in both tray supported engagement and cylinder supporting engagement, at each said tray-cylinder interface station, the lower edge extends below the upper edge.

4. The system of claim 3, comprising an array cover having a cover upper portion, a cover lower portion, a cover lateral periphery, and a two-dimensional array of cover-cylinder interface stations, wherein(a) the array cover is configured to be placed in cover supported engagement with a said gas cylinder layer disposed downwardly thereof;(b) each said cover-cylinder interface station includes a collar receiving portion; and(c) in the cover supported engagement, each said cover-cylinder interface station is configured to aligningly receive the collar of a respective downwardly disposed said gas cylinder by way of the collar receiving portion.

5. The system of claim 4, wherein(a) each said cover-cylinder interface station includes an upper dome engagement portion disposed along the cover lower portion; and(b) in the cover supported engagement, each said cover-cylinder interface station is configured to engage the upper dome of a respective downwardly disposed said gas cylinder by way of the upper dome engagement portion.

6. The system of claim 4, wherein each said collar receiving portion includes a collar aperture extending therethrough, the collar aperture being configured for a said collar to extend through the collar aperture in the cover supported engagement.

7. The system of claim 4, wherein(a) the array cover includes a plurality of cover stiffener segments each defining a cover stiffener channel; and(b) each said cover stiffener segment extends between a pair of said cover-cylinder interface stations.

8. The system of claim 7, wherein(a) the array cover includes a plurality of cover stiffener ribs; and(b) at least a subset of the cover stiffener ribs each extends between a pair of said cover stiffener segments extending in parallel with one another.

9. The system of claim 4, wherein(a) the array cover includes a plurality of cover strap interface portions disposed along the cover lateral periphery;(b) each said pallet tray includes a plurality of tray strap interface portions disposed along the tray lateral periphery; and(c) the array cover and the one or more pallet trays are configured to be secured in strapped engagement with one another by way of the cover strap interface portions and the tray strap interface portions.

10. The system of claim 9, wherein(a) each said tray strap interface portion includes a tray strap detent configured to restrict lateral movement of a securement strap relative to the tray strap interface portion in the strapped engagement; and(b) each said cover strap interface portion includes a cover strap detent configured to restrict lateral movement of a securement strap relative to the cover strap interface portion in the strapped engagement.

11. The system of claim 9, wherein(a) each said tray strap interface portion includes a tray strap aperture extending therethrough, the tray strap aperture being configured for a securement strap to extend through the tray strap aperture in the strapped engagement; and(b) each said cover strap interface portion includes a cover strap aperture extending therethrough, the cover strap aperture being configured for a securement strap to extend through the cover strap aperture in the strapped engagement.

12. The system of claim 11, wherein(a) each said tray strap interface portion includes a tray strap aperture sleeve disposed inboard of the tray lateral periphery, each said tray strap aperture sleeve defining an outer periphery of a corresponding said tray strap aperture; and(b) each said cover strap interface portion includes a cover strap aperture sleeve disposed inboard of the cover lateral periphery, each said cover strap aperture sleeve defining an outer periphery of a corresponding said cover strap aperture.

13. The system of claim 11, wherein(a) the tray lateral periphery includes a tray peripheral wall having a tray strap relief at each tray strap interface portion, each said tray strap relief being configured to engage an outer segment of a securement strap in the strapped engagement; and(b) each said tray strap aperture is disposed inboard of a respective said tray strap relief, the tray strap aperture being configured to receive a corresponding inboard segment of a securement strap in the strapped engagement.

14. The system of claim 11, wherein(a) the cover lateral periphery includes a cover peripheral wall having a cover strap relief at each cover strap interface portion, each said cover strap relief being configured to engage an outer segment of a securement strap in the strapped engagement; and(b) each said cover strap aperture is disposed inboard of a respective said cover strap relief, the cover strap aperture being configured to receive a corresponding inboard segment of a securement strap in the strapped engagement.

15. The system of claim 4, wherein the one or more pallet trays and the array cover are each comprised of injection-molded polymer.

16. The system of claim 1, comprising a plurality of pallet feet, each said pallet foot having an outer wall, a base portion for engaging a local horizontal surface, and a pallet foot upper edge, wherein(a) each said pallet tray is configured to be placed in pallet supported engagement with the plurality of pallet feet; and(b) in the pallet supported engagement, each said tray-cylinder interface station is configured to aligningly engage the pallet foot upper edge of a respective said pallet foot by way of the lower alignment portion.

17. The system of claim 16, whereineach said pallet foot includes one or more pallet foot securement members;each said lower alignment portion includes one or more pallet foot retention apertures extending therethrough; andeach said pallet foot is configured to be secured to a respective said lower alignment portion by way of secured engagement between respective said pallet foot securement members and corresponding said pallet foot retention apertures.

18. The system of claim 17, wherein each of the one or more pallet foot securement members comprise cantilever snaps.

19. The system of claim 16, comprising a two-dimensional array of said pallet feet; wherein(a) in the pallet supported engagement,(i) a plurality of fork relief zones are each defined between adjacently disposed columns of the two-dimensional array of said pallet feet;(ii) a plurality of fork relief zones are each defined between adjacently disposed rows of the two-dimensional array of said pallet feet; and(b) the fork relief zones are each configured to receive a fork of a forklift.

20. The system of claim 1, wherein(a) each said pallet tray includes a plurality of tray stiffener segments each defining a tray stiffener channel; and(b) each said tray stiffener segment extends between a pair of said tray-cylinder interface stations.

21. The system of claim 20, wherein(a) each said pallet tray includes a plurality of tray stiffener ribs; and(b) at least a subset of the tray stiffener ribs each extends between a pair of said tray stiffener segments extending in parallel with one another.

22. A system for palletizing gas cylinders into one or more gas cylinder layers, the system comprising:a plurality of pallet trays including a lowermost pallet tray and an uppermost pallet tray, each said pallet tray having a tray upper portion, a tray lower portion, a tray lateral periphery, and a two-dimensional array of tray-cylinder interface stations;a plurality of gas cylinder layers including an uppermost gas cylinder layer and a lowermost gas cylinder layer, each said gas cylinder layer comprising a horizontal two-dimensional array of gas cylinders; andan array cover having a cover upper portion, a cover lower portion, a cover lateral periphery, and a two-dimensional array of cover-cylinder interface stations;wherein,(a) by way of the tray-cylinder interface stations,(i) each said tray upper portion is configured for cylinder supporting engagement with any one of the gas cylinder layers; and(ii) each said tray lower portion is configured for tray supported engagement with any one of the gas cylinder layers;(b) by way of the cover-cylinder interface stations, the cover lower portion is configured for cover supported engagement with any one of the gas cylinder layers;(c) for the lowermost pallet tray, the tray lower portion is configured for resting engagement with a local horizontal surface and the tray upper portion is in cylinder supporting engagement with the lowermost gas cylinder layer;(d) for the uppermost pallet tray, the tray lower portion is in tray supported engagement with one of the gas cylinder layers and the tray upper portion is in cylinder supporting engagement with the uppermost gas cylinder layer; and(e) the cover lower portion of the array cover is in cover supported engagement with the uppermost gas cylinder layer.

23. The system of claim 22, whereinthe plurality of pallet trays include one or more intermediate pallet trays disposed between the lowermost pallet tray and the uppermost pallet tray; andthe plurality of gas cylinder layers include one or more intermediate gas cylinder layers disposed between the lowermost gas cylinder layer and the uppermost gas cylinder layer.

24. The system of claim 22, wherein(a) each said gas cylinder has an upper dome, a lower dome, a collar extending upward from the upper dome, and a foot ring extending downward from the lower dome;(b) each said tray-cylinder interface station includes a lower alignment portion disposed along the tray lower portion and a foot ring alignment channel disposed along the tray upper portion;(c) each said cover-cylinder interface station includes a collar receiving portion;(d) in the tray supported engagement, a respective said tray-cylinder interface station is aligningly engaged with the collar of a respective downwardly disposed said gas cylinder by way of the lower alignment portion;(e) in the cylinder supporting engagement, a respective said tray-cylinder interface station aligningly receives the foot ring of a respective upwardly disposed said gas cylinder by way of the foot ring alignment channel; and(f) in the cover supported engagement, a respective said cover-cylinder interface station aligningly receives the collar of a respective downwardly disposed said gas cylinder by way of the collar receiving portion.

25. The system of claim 24, wherein(a) each said foot ring includes a lower edge and each said collar includes an upper edge;(b) for each said tray-cylinder interface station, the foot ring alignment channel extends downwardly of the lower alignment portion; and(c) for a said pallet tray in both tray supported engagement and cylinder supporting engagement, at each said tray-cylinder interface station, the lower edge extends below the upper edge.

26. The system of claim 22, wherein(a) the array cover includes a plurality of cover strap interface portions disposed along the cover lateral periphery;(b) each said pallet tray includes a plurality of tray strap interface portions disposed along the tray lateral periphery; and(c) the array cover and the pallet trays are secured in strapped engagement with one another by way of the cover strap interface portions and the tray strap interface portions.

27. The system of claim 22, comprising a two-dimensional array of pallet feet, each said pallet foot having an outer wall, a base portion for engaging a local horizontal surface, and a pallet foot upper edge, wherein(a) the lowermost pallet tray is in pallet supported engagement with the pallet feet;(b) in the pallet supported engagement,(i) each respective said tray-cylinder interface station is aligningly engaged with the pallet foot upper edge of a corresponding said pallet foot by way of the lower alignment portion;(ii) a plurality of fork relief zones are each defined between adjacently disposed columns of the two-dimensional array of said pallet feet; and(iii) a plurality of fork relief zones are each defined between adjacently disposed rows of the two-dimensional array of said pallet feet; and(c) the fork relief zones are each configured to receive a fork of a forklift.

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