Modular pallet and assembly method thereof

Abstract

Modular pallet and assembly method thereof Modular pallet comprising: a frame, at least four support devices, a rectangular-shaped initial deck element, a rectangular-shaped final deck element, and optionally, at least one rectangular-shaped intermediate deck element. The frame comprises three longitudinal bars and, optionally, at least one cross bar. Each deck element comprises, on its lower face: three longitudinal guide devices, said longitudinal guide devices having a configuration such as to receive one of said longitudinal bars; at least one transverse guide device in each of the deck elements, said transverse guide devices having a configuration such as to receive one of said cross bars. Fastening devices fasten said support devices to said deck elements, such that the frame is fitted and locked between the support devices and the deck elements.

Description

[0001] Modular pallet and assembly method thereof

[0002] Field of the invention

[0003] The present invention relates to a modular pallet. Pallets comprise a deck, which has a surface on which the load rests, and one or more support devices, usually in the form of a block, which support the deck and which rest on the floor, a warehouse shelf, the floor of a trailer, etc. The loading surface may or may not be continuous. The deck and support devices may be integral or independent pieces connected to each other.

[0004] The present invention is thus framed within the sector of transport, storage, and / or handling of goods.

[0005] Background of the invention

[0006] Modular pallets exist in the sector. However, modular pallets suffer from certain shortcomings because they present low resistance, contain a large amount of material, are bulky, offer few possibilities in terms of the dimensions they can present once assembled and / or require complicated assembly / disassembly procedures.

[0007] Document EP1266835 discloses a modular pallet assembled from a set of modules with few types of modules. In fact, there are only two types of modules, namely the segments, which once juxtaposed form the deck and the supports, and the bars, which pass through the segments of the assembled pallet and join them together. This pallet thereby allows for quick and easy assembly. However, the segments have a lot of material and form a bulky pallet. In fact, as an alternative, the pallet can be assembled with a third type of module, namely a spacer. Spacers replace a certain number of segments. This reduces the amount of material and bulkiness of the pallet, but at the expense of its rigidity and / or strength. The amount of material and bulkiness of the pallet can also be reduced by combining integrally supported segments with unsupported segments, but this does not lead to significant relief.

[0008] Document FR3028247 discloses a modular pallet with a multitude of module types. The pallet is basically assembled from bars (1), perforated segments (2), tightening screws (4), perforated extension pieces (7), supports (6) and fixings (11). The extension pieces are placed on the segments so that their holes match, then the bars slide through the holes keeping the latter aligned, the tightening screws are applied, the supports are fitted into the bars, and the fixings are applied. It is a pallet that requires a laborious assembly procedure.

[0009] Explanation of the invention

[0010] The present invention therefore refers, in a first aspect, to a modular pallet comprising: at least four support devices, a frame resting on said support devices, a rectangular-shaped initial deck element, which rests on said frame, a rectangular-shaped final deck element, resting on said frame, and optionally, at least one rectangular-shaped intermediate deck element, resting on said frame.

[0011] The pallet deck elements, arranged horizontally, coplanar and adjacent by their longer sides, form the pallet deck and define a longitudinal, horizontal and parallel axis to the shorter sides of the pallet elements, and a transverse, horizontal and parallel axis to the longer sides of the pallet elements.

[0012] The frame comprises two or three longitudinal bars and, optionally, at least one cross bar. It will have a configuration adapted to the desired use for the pallet.

[0013] Each deck element comprises, on its lower face, a longitudinal guide device at a first end of the corresponding deck element, a longitudinal guide device at a second end of the corresponding deck element, and a longitudinal guide device at the centre of the corresponding deck element, one of said longitudinal bars being received in said first end longitudinal guide devices, one of said longitudinal bars being received in said second end longitudinal guide devices, and optionally one of said longitudinal bars being received in said central longitudinal guide devices. Optionally, at least one deck element comprises, on its lower face, a transverse guide device, said transverse guide devices having a configuration such as to receive one of said cross bars, optionally one of said cross bars being received in said transverse guide devices.

[0014] These guide devices are open at the bottom.

[0015] Preferably, each of the deck elements is an injected piece and said guide devices are made by integral reliefs of the deck elements. Optionally, the lower surface of the deck elements comprises integral stiffening reliefs. Optionally, the upper surface of the pallet elements comprises integral edge projections situated such that, in the assembled condition of the pallet, they form a continuous vertical rim at the periphery of the pallet. Optionally, said integral edge projections comprise through holes intended to drain liquids that may become trapped in said rim.

[0016] The initial deck element comprises at least one recess on one of its longer sides. The final deck element comprises at least one projection on one of its longer sides. Each of the intermediate deck elements comprises at least one projection on one of its longer sides and at least one recess on the other of its longer sides. Said projections and said recesses are situated such that each of said projections is received in one of said recesses.

[0017] Preferably, all projections have the same shape as each other and all recesses have the same shape as each other. The projections and recesses are preferably dovetailed.

[0018] Each support device comprises a housing having a configuration such as to receive said frame. A support device is situated in correspondence with each end of the initial deck element and the final deck element. Optionally, a support device is located in correspondence with at least one of the ends of at least one of the intermediate deck elements and / or with the centre of at least one of the deck elements.

[0019] Each support device is fixed by means of fastening devices to the corresponding deck element. Such fastening devices are screws, rivets or similar. The present invention relates, in a second aspect, to a method of assembling the modular pallet of the invention, which comprises the following steps:

[0020] - arranging a positioning template, which indicates the position of the support devices to be used,

[0021] - arranging a support device in each of the positions indicated by the template,

[0022] - arranging the frame on the arranged support devices,

[0023] - arranging said initial deck element on said frame, in correspondence with the support devices at one longitudinal end of the pallet,

[0024] - arranging said final deck element by applying the project! on(s) of said final deck element into the respective recess(es) of said initial deck element such that the deck elements are arranged coplanar with each other on said frame,

[0025] - arranging said fastening devices across the deck elements and in correspondence with each support device, such that each support device is fixed to the corresponding deck element by means of said fastening devices.

[0026] The present invention relates, in a third aspect, to a method of assembling the modular pallet of the invention, which comprises the following steps:

[0027] - arranging a positioning template, which indicates the position of the support devices to be used,

[0028] - arranging a support device in each of the positions indicated by the template,

[0029] - arranging the frame on the arranged support devices,

[0030] - arranging said initial deck element on said frame, in correspondence with the support devices at one longitudinal end of the pallet,

[0031] - arranging an intermediate deck element by applying the projection(s) of said intermediate deck element into the respective recess(es) of the initial deck element, such that the deck elements are arranged coplanar with each other on said frame,

[0032] - optionally, arranging an intermediate deck element by applying the projection(s) of said intermediate deck element into the respective recess(es) of the intermediate deck element arranged immediately before, such that the deck elements are arranged coplanar with each other on said frame,

[0033] - optionally, repeat the previous step at least once,

[0034] - arranging said final deck element by applying the projection(s) of said final deck element into the respective recess(es) of the intermediate deck element arranged immediately before, such that the deck elements are arranged coplanar with each other on said frame,

[0035] - arranging said fastening devices across the deck elements and in correspondence with each support device, such that each support device is fixed to the corresponding deck element by means of said fastening devices.

[0036] The frame is fitted and locked between the support devices and the deck itself. In this way, the connection between the different deck elements is fixed. The pallet is not intended to be dismantled once the support devices and frame have been fixed.

[0037] It should be noted that with the present invention a modular pallet can be achieved that is resistant and easy to assemble, highly versatile, and with a smooth and continuous bottom.

[0038] In this document, terms referring to a location or position, such as “upper,” “lower,” “horizontal,” or “vertical,” are to be understood in relation to the assembled condition of a pallet in its position of use. Likewise, the terms “longitudinal” or “transverse” must be understood in relation to the longitudinal and transverse axes, respectively, as defined herein.

[0039] Brief description of the drawings

[0040] The characteristics and advantages of the present invention will become clearer from the following detailed description of embodiments thereof, described, by way of non-limiting example, with reference to the attached drawings, wherein:

[0041] Figure 1 is a top perspective view of a modular pallet according to an embodiment of the present invention,

[0042] Figure 2 represents a bottom perspective view of the pallet of Figure 1,

[0043] Figure 3 a top plan view of the pallet of Figure 1,

[0044] Figure 4 is a perspective view, partially orderly exploded, of the pallet of Figure 1,

[0045] Figure 5 is a perspective view, partially orderly exploded, of the pallet of Figure 1,

[0046] Figure 6 is a detailed view of box VI of Figure 1,

[0047] Figure 7 is a cross-sectional view, in the longitudinal direction of the pallet, of the pallet of Figure 1, Figure 8A is a cross-sectional view, in the transverse direction of the pallet, of the pallet of Figure 1, and

[0048] Figure 8B is a detailed view of box VIII of Figure 8 A.

[0049] Parts common to more than one figure are identified with the same references in all figures.

[0050] Detailed description of the invention

[0051] The figures show a pallet 100 according to an embodiment of the present invention.

[0052] Said pallet 100 comprises five slatted deck elements, namely an initial slat 6, a final slat 8 and three intermediate slats 10. It is preferable, but not necessary, that all the slats that make up a single pallet have the same longitudinal dimension.

[0053] Each of said slats 6, 8, 10 has three longitudinal guides 16, one at each transverse end and one in the centre, on the lower face of each of said slats 6, 8, 10.

[0054] Three longitudinal bars 2 forming a frame are placed on the lower face of the pallet 100, parallel to each other and to the shorter sides of the slats 6, 8, 10, applied to said longitudinal guides 16, although the longitudinal bar 2 applied to the central longitudinal guides 16 is optional.

[0055] Finally, the pallet 100 is provided with nine support devices in the form of a block 12. Six of said blocks 12 are applied to the initial slat 6 and to the final slat 8, and the other three of said blocks 12 are applied to the intermediate slat 10 located in the centre of the pallet. Said blocks 12 each have a housing for receiving said longitudinal bars 2 and, optionally, lateral bars. In the present embodiment, said housing is created by cylindrical vertical projections 13 of each block 12 projecting from the block body of each block 12. The blocks 12 arranged at the ends of the slats 6, 8, 10 have two of said projections 13, aligned longitudinally, while the blocks arranged in the centre of the slats 6, 8, 10 have four projections, arranged quadrangularly. In this way, the blocks 12 have a housing that can receive both the longitudinal bars 2 and a possible cross bar, in case the longitudinal bar 2 is omitted. Pallet 100 is also provided with transverse guides 18, although this characteristic is optional and could thus be omitted. In fact, in the present embodiment, said transverse guides 18 are not in use, since the pallet 100 does not comprise cross bars. In the present embodiment, the central longitudinal bar 2 has to be omitted to allow the possibility of placing cross bars.

[0056] In the present embodiment, both the longitudinal guides 16 and the transverse guides 18 are made by continuous vertical integral reliefs of the slats 6, 8, 10, which form longitudinal and transverse channels, respectively. However, the guides may be made by other arrangements, such as for example a plurality of accessory discrete vertical integral reliefs, fastened to the lower face of the slats, etc. The characteristic that the guides must have is that they have a suitable configuration so that the bars are applied to them in the predetermined direction (longitudinal or transverse).

[0057] The final slat 8 has four dovetailed projections 22 on one of its longer sides. Each of said intermediate slats 10 has four dovetailed projections 22 on one of its longer sides, and has at least four recesses 20 on the other of its longer sides, in the form of recesses on its lower face, not visible, which are complementary to said projections 22 and are situated in correspondence therewith. Finally, the initial slat 6 has at least four recesses 20 on one of its longer sides, in the form of recesses on its lower face, which are complementary to said projections 22 and are situated in correspondence therewith.

[0058] In the present embodiment, the slats comprise vertical through holes 30 prearranged in standardised locations, intended to be passed through by block fastening screws 31. The head of screw 31 is fixed to a slat and screw 31 is screwed into the corresponding block. These holes are optional and, even if they are present, they may or may not be used, part of them or all of them, depending on the specific characteristics of the embodiment. In the present embodiment, vertical through holes 30 are used in correspondence with the blocks 12 that have been arranged.

[0059] In this embodiment, all the projections 22 are the same as each other and all the recesses are the same as each other. In addition, all the projections 22 and all the recesses are distributed along the longer sides of the slats 6, 8, 10 in such a way that they are longitudinally aligned.

[0060] Moreover, all the slats 6, 8, 10 have the same dimension in longitudinal direction.

[0061] It is preferable, but not necessary, that all the projections be the same as each other, all the recesses be the same as each other, and all the projections and all the recesses be distributed along the longer sides of the slats in such a way that they are longitudinally aligned. It is also preferable to have a range of slats of various dimensions in the longitudinal direction, in order to combine them as appropriate to obtain pallets of suitable longitudinal dimensions. This creates a very versatile pallet system with a reduced range of slats, adding multiple intermediate slats as needed and maintaining the two initial and final slats.

[0062] In the present embodiment, the slats are injection pieces, which are relatively quick and easy to produce, so a flexible and on-demand production system can be envisaged, which provides greater versatility to the preparation of pallets in accordance with the present invention.

[0063] The pallet 100 has integral stiffening reliefs 24 on the lower surface of the pallet 100, and the upper surface of the pallet 100 comprises a continuous vertical rim 26 situated at the periphery of the pallet 100. In the present embodiment, said rim 26 is formed with a perimeter recess 32, useful for locating a perimeter collar, and a step 28, useful for assembling a return strip.

[0064] In order to assemble said pallet 100, the following steps are implemented:

[0065] - arranging a positioning template, which indicates the position of the nine 12 blocks to be used,

[0066] - arranging a block 12 in each of the positions indicated by the template,

[0067] - arranging said longitudinal bars 2 on the arranged blocks 12,

[0068] - arranging said initial slat 6 on said longitudinal bars 2, in correspondence with the blocks 12 of one longitudinal end of the pallet,

[0069] - arranging an intermediate slat 10 by applying the projections 22 of said intermediate slat 10 to the respective recesses 20 of the initial slat 6, such that the slats 6, 10 are arranged coplanar with each other on said longitudinal bars 2,

[0070] - arranging an intermediate slat 10 by applying the projections 22 of said intermediate slat 10 to the respective recesses 20 of the intermediate slat 10 arranged immediately before, such that the slats 6, 10 are arranged coplanar with each other on said longitudinal bars 2,

[0071] - repeat the previous step until all the intermediate slats 10 that form the pallet 100 are arranged, - arranging said final slat 8 by applying the projections 22 of said final slat 8 into the respective recesses 20 of the intermediate slat 10 arranged immediately before, such that the slats 6, 8, 10 are arranged coplanar with each other on said longitudinal bars 2,

[0072] - arranging said screws 31 through the slats 6, 8, 10 and in correspondence with each block 12, so that each block 12 is fixed to the corresponding slat 6, 8, 10 by means of said screws 31.

[0073] Naturally, while maintaining the principle of the invention, the embodiments and construction details can be widely varied with respect to what is described and illustrated without departing from the scope of the present invention.

Claims

CLAIMS1. Modular pallet comprising: at least four support devices, a frame resting on said support devices, a rectangular-shaped initial deck element, which rests on said frame, a rectangular-shaped final deck element, resting on said frame, and optionally, at least one rectangular-shaped intermediate deck element, resting on said frame; wherein the pallet deck elements, arranged horizontally, coplanar and adjacent by their longer sides, form the pallet deck; characterised in that: the frame comprises two or three longitudinal bars and, optionally, a cross bar; each deck element comprises, on its lower face, a longitudinal guide device at a first end of the corresponding deck element, a longitudinal guide device at a second end of the corresponding deck element, and a longitudinal guide device at the centre of the corresponding deck element, one of said longitudinal bars being received in said first end longitudinal guide devices, one of said longitudinal bars being received in said second end longitudinal guide devices, and optionally one of said longitudinal bars being received in said central longitudinal guide devices, said longitudinal guide devices being open at the bottom; corresponding to each end of the initial deck element and the final deck element is a support device, each support device comprising a housing having a configuration such as to receive said frame; the initial deck element comprises at least one recess on one of its longer sides, the final deck element comprises at least one projection on one of its longer sides, each of the intermediate deck elements comprises at least one projection on one of its longer sides and at least one recess on the other of its longer sides, said projections and said recesses being positioned such that each of said projections is received in one of said recesses; each support device is fixed by means of fastening devices to the corresponding deck element.

2. Modular pallet according to claim 1, characterised in that at least one deck element comprises, on its lower face, a transverse guide device, said transverse guide device having a configuration such as to receive a cross bar, said transverse guide device being open at the bottom.

3. Modular pallet according to claim 2, characterised in that a cross bar of said frame is received in said transverse guide device.

4. Modular pallet according to any one of the preceding claims, characterised in that said fastening devices are screws and / or rivets.

5. Modular pallet according to any one of the preceding claims, characterised in that a support device is situated in correspondence with at least one of the ends of the intermediate deck elements and / or with the centre of at least one of the deck elements, each support device comprising a housing having a configuration such as to receive said frame.

6. Modular pallet according to any one of the preceding claims, characterised in that all the projections have the same shape as each other and all the recesses have the same shape as each other.

7. Modular pallet according to any one of the preceding claims, characterised in that all the projections and recesses are dovetailed.

8. Modular pallet according to any one of the preceding claims, characterised in that each of the deck elements is an injected piece and said guide devices are made by means of integral reliefs of the deck elements.

9. Modular pallet according to any one of the preceding claims, characterised in that the upper surface of the deck elements comprises integral edge projections located such that, in the assembled condition of the pallet, they form a continuous vertical rim on the periphery of the pallet.

10. Modular pallet according to any one of the preceding claims, characterised in that at least one deck element comprises at least one vertical through hole, each of said through holes being intended to be traversed by said fastening devices.

11. Modular pallet according to any one of the preceding claims, characterised in that each support device has cylindrical vertical projections that create said housing.

12. Modular pallet according to claim 11, characterised in that the support devices arranged at the ends of the deck elements have two of said projections, aligned longitudinally, while the support devices arranged in the centre of the deck elements have four of said projections, arranged quadrangularly.

13. Method for assembling a modular pallet according to any one of claims 1 to 12, characterised in that it comprises the following steps:- arranging a positioning template, which indicates the position of the support devices to be used,- arranging a support device in each of the positions indicated by the template,- arranging the frame on the arranged support devices,- arranging said initial deck element on said frame, in correspondence with the support devices at one longitudinal end of the pallet,- arranging said final deck element by applying the project! on(s) of said final deck element into the respective recess(es) of said initial deck element such that the deck elements are arranged coplanar with each other on said frame,- arranging said fastening devices across the deck elements and in correspondence with each support device, such that each support device is fixed to the corresponding deck element by means of said fastening devices.

14. Method for assembling a modular pallet according to any one of claims 1 to 12, characterised in that it comprises the following steps:- arranging a positioning template, which indicates the position of the support devices to be used,- arranging a support device in each of the positions indicated by the template,- arranging the frame on the arranged support devices,- arranging said initial deck element on said frame, in correspondence with the support devices at one longitudinal end of the pallet,- arranging an intermediate deck element by applying the project! on(s) of said intermediate deck element into the respective recess(es) of the initial deck element, such that the deck elements are arranged coplanar with each other on said frame,- optionally, arranging another intermediate deck element by applying the projection(s) of said intermediate deck element into the respective recess(es) of the intermediate deck element arranged immediately before, such that the deck elements are arranged coplanar with each other on said frame,- optionally, repeat the previous step at least once,- arranging said final deck element by applying the projection(s) of said final deck element into the respective recess(es) of the intermediate deck element arranged immediately before, such that the deck elements are arranged coplanar with each other on said frame, - arranging said fastening devices across the deck elements and in correspondence with each support device, such that each support device is fixed to the corresponding deck element by means of said fastening devices.

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