Reusable wrapping system and method for securing a load to a pallet

Abstract

A pallet wrapping system and method of wrapping a load on a pallet are provided. The pallet wrapping system includes a pallet that has disposed within it, on at least two sides, a rolled pallet wrap that is unwound around a load when in use and rewound back on the roll when not in use. The pallet wrap is, therefore, stored attached to the pallet between uses.

Description

REUSABLE WRAPPING SYSTEM AND METHOD FOR SECURING A LOAD TO A PALLETCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 666,742 filed on July 2, 2024, entitled “REUSABLE WRAPPING SYSTEM AND METHODFOR SECURING A LOAD TO A PALLET.”FIELD OF THE INVENTION

[0002] This disclosure relates to a pallet wrapping system and method for securing a load to a pallet using a reusable pallet wrap. The wrap unrolls during use and rerolls after use, to be stored attached to the pallet between uses.BACKGROUND OF THE INVENTION

[0003] Pallets having slots for receiving the forks of a forklift or similar lifting device are used in various industries for storage, stacking, and transportation of goods. Goods stacked on a pallet need to be secured to the pallet for shipping and / or storage so that the load does not shift during transportation and remains attached to the pallet itself. It is common to use a plastic shrink wrap or stretch wrap to secure loads to pallets. The plastic wrap is wrapped around and around the load several times to cover the surface of the load, and around the pallet itself to connect the load to the pallet. Plastic also protects the load against weather-related damage from snow, rain, sun and wind. However, this plastic is not reused or recycled and is thus a single-use product. One big box store will easily discard over 175,000 pounds of plastic per year into a landfill. Alternative wraps such as compostable wraps produce methane gas when they break down, and biodegradable plastics do not degrade when they are buried in the ground and therefore are not ideal alternatives to single-use plastics.

[0004] Re-usable pallet wraps and systems are known but have not replaced single use plastics. Generally, they are difficult for an individual working alone to use, are big and bulky to store when not in use, and typically do not provide a reliable means to secure the load relative to the pallet itself. For example, US Patent No. 7,934,894 to Temple discloses a reusable pallet wrap for securing loads on pallets. The wraps come in various sizes for use with different sized loads and are secured around the load using straps of Velcro and D-rings. They secure the load to thepallet with a few tiny straps. These wraps are big and bulky to store when not in use and are time-consuming to apply to the load and pallet. Various other attempts have been made to provide an alternative to single use plastics and to solve these problems, such as those found in US Patent No. 4,738,371 to Wakeman, US Patent No. 9,162,805 to Testa et al., US Patent Publication No. 2019 / 0031414 to Anderson, WO 2005 / 068310 to Gab, and W02021 / 001843 to Brahmbhatt et al. While not ideal, single use plastic wrap is still the most prevalent wrapping material in this industry since it is still easier to use and less expensive than the available alternatives. There remains therefore a need for a pallet wrapping system and method that uses a reusable wrap and is easy and economical to use.SUMMARY OF THE INVENTION

[0005] The present invention relates to a pallet wrapping system and method for securing a load to a pallet using a reusable pallet wrap. The pallet wrapping system includes a pallet that has disposed within it, on at least two sides, a rolled pallet wrap that is unwound around a load when in use and rewound back on the roll when not in use. The pallet wrap is, therefore, stored attached to the pallet between uses.

[0006] Broadly, in one aspect, the invention comprises a pallet comprising: a) an upper load-bearing surface and a lower ground-facing surface; b) a first side having a first compartment, wherein the first compartment extends substantially along the entire length of the first side; c) a second side perpendicular to the first side, having a second compartment, wherein the second compartment extends substantially along the entire length of the second side; d) a first roll of pallet wrapping material disposed in the first compartment substantially along the entire length of the first compartment; e) a second roll of pallet wrapping material disposed in the second compartment substantially along the entire length of the second compartment; f) a first opening in the first compartment, the first opening sized to enable unrolling of the first wrapping material from the first roll by pulling on a free end of the first wrapping material;g) a second opening in the second compartment, the second opening sized to enable unrolling of the second wrapping material from the second roll by pulling on a free end of the second wrapping material; and h) means for securing the free end of the first wrapping material and the free end of the second wrapping material to the pallet.

[0007] In some embodiments, the upper load-bearing surface is formed by a deck unit comprising a plurality of adjoining boards including at least two boards removably covering the first and second compartments. In some embodiments, the lower ground-facing surface is formed by a base unit comprising one or more cut-outs for reducing weight and one or more notches for receiving and accommodating a lifting device. In some embodiments, the deck unit and the base unit cooperate to form the first compartment, the second compartment, the first opening, and the second opening.

[0008] In some embodiments, the first roll comprises the first wrapping material wound around a first rod member of a first roll assembly, the first rod member comprising an elongate shaft and first and second ends attachable within the first compartment by attachment means; and the second roll comprises the second wrapping material wound around a second rod member of a second roll assembly, the second rod member comprising an elongate shaft and first and second ends attachable within the second compartment by attachment means.

[0009] In some embodiments, the first roll assembly further comprises first rotating means for rotating the first rod member to unroll and reroll the first wrapping material around the first rod member; and the second roll assembly further comprises second rotating means for rotating the second rod member to unroll and reroll the second wrapping material around the second rod member. In some embodiments, the first and second rod members are linked with a gear set and a coupling to enable simultaneous rotation of the first and second rod members to unroll and reroll the first and second wrapping materials.

[0010] In some embodiments, the pallet further comprises tightening means for rerolling the first and second wrapping materials around the first and second rod members, the tightening means being selected from a gear assembly, a spring, or hook and loop fasteners and corresponding rings. In some embodiments, the pallet further comprises releasable locking means for locking and unlocking the first and second rod members to prevent or allow rotation thereof. In some embodiments, the releasable locking means comprises a gear assembly, the gearassembly comprising a pawl for engagement with a gear in a locked position preventing rotation, and for disengagement with the gear in an unlocked position allowing rotation. In some embodiments, the releasable locking means comprises a housing assembly housing a ratchet and locking mechanism slider actuated by a pair of slider knobs.

[0011] In some embodiments, the means for securing the free end of the first wrapping material and the free end of the second wrapping material to the pallet are selected from connectors releasably connectable to receivers; a grab bracket; strips of hook and loop fasteners insertable into corresponding rings; or a plurality of metal hooks or carabiners releasably connectable to eyes.

[0012] In some embodiments, the pallet is formed of wood or plastic. In some embodiments, the first and second wrapping materials are formed of plastic, cotton, burlap, fiberglass, nylon, rubber, or any combination thereof. In some embodiments, the first and second wrapping materials are reusable. In some embodiments, the pallet further comprises one or more tracking devices.

[0013] In a second aspect, the invention comprises a method of securing a load to the top of a pallet, the method comprising: a) stacking a load onto a pallet; b) unrolling a first wrapping material from a first roll of pallet wrapping material that is attached to a first side of the pallet by pulling on a free end of the first wrapping material; c) covering two sides of the load and the top of the load with the first wrapping material; d) securing the free end of the first wrapping material to the pallet; e) unrolling a second wrapping material from a second roll of pallet wrapping material that is attached to a second side of the pallet by pulling on a free end of the second wrapping material; f) covering two sides of the load and the top of the load with the second wrapping material; g) securing the free end of the second wrapping material to the pallet; wherein the first roll of wrapping material extends substantially along the entire first side of the pallet, andwherein the second roll of wrapping material extends substantially along the entire second side of the pallet.

[0014] In some embodiments, the method further comprises tightening the first and second wrapping materials about the load using tightening means. In some embodiments, the method further comprises actuating locking means to prevent further unrolling of the first and second wrapping materials from the first and second rolls.

[0015] Additional aspects and advantages of the present invention will be apparent in view of the description which follows. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the scope of the invention will become apparent to those skilled in the art from this detailed description.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The invention will now be described by way of an exemplary embodiment with reference to the accompanying simplified, diagrammatic, not-to-scale drawings. In the drawings:

[0017] FIGS. 1A-D show a first embodiment of the pallet wrapping system, showing perspective views of: the base unit (FIG. 1A), the base unit with the deck unit attached (FIG. IB), the bottom of the base unit with the deck unit attached (FIG. 1C); and the assembled pallet with the wrapping material pulled out and over the deck unit (FIG. ID).

[0018] FIGS. 2A-B are exploded perspective views of a first embodiment of the pallet wrapping system from the front (FIG. 2A) and back (FIG. 2B). The components shown are the base unit, the deck unit, first and second wrapping materials extended over and around the deck unit, connectors, receivers, and ider end assemblies for the roll assembly.

[0019] FIG. 3 is an exploded perspective view of a first embodiment of the pallet wrapping system. The components shown are the base unit, the deck unit, first and second wrapping materials extended over and around the deck unit, connectors, receivers, and ider end assemblies for the roll assembly.

[0020] FIGS. 4A-C show details of the top of a first embodiment of the pallet showing the pallet deck unit (FIG. 4A), a side view of the pallet showing the connectors and an end of a roll assembly (FIG. 4B), and a side perspective view of the pallet showing the connectors and end of a roll assembly in a compartment of the pallet (FIG. 4C).

[0021] FIG. 5 shows an embodiment of a roll assembly that is removed from the pallet.

[0022] FIG. 6 shows the details of an embodiment of the end of the roll assembly of FIG. 5.

[0023] FIGS. 7A-C show an exploded view of an embodiment of the components making up the end of the roll assembly of FIG. 5 (FIG. 7A), the components assembled (FIG. 7B) and partially in cross-section (FIG. 7C).

[0024] FIG. 8A shows an exploded perspective view of a second embodiment of the pallet wrapping system. The components shown are the base unit, the deck unit, first and second wrapping materials, a grab bracket, and components making up the end of the roll assembly.

[0025] FIG. 8B shows an exploded view of the details of an embodiment of the end of the roll assembly of FIG. 8 A. The component shown is an end bearing holder.

[0026] FIG. 8C shows an exploded view of the details of an embodiment of the end of the roll assembly of FIG. 8A. The component shown is a second embodiment of a releasable locking device.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] Before the present invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein. The term “horizontal” means the orientation of a plane or line that is substantially parallel to the plane of the horizon. The term “vertical” means the orientation of a plane or line that is substantially at a right angle to the horizontal plane.

[0028] Generally, a pallet wrapping system and method of wrapping a load on a pallet are disclosed herein. The pallet wrapping system comprises a pallet that has disposed within it, on at least two sides, a rolled pallet wrap that is unwound around a load when in use and rewound back on the roll when not in use. The pallet wrap is, therefore, stored attached to the palletbetween uses. The load on the pallet may be any plurality of items stacked on the pallet, or a single item on the pallet. Embodiments of the invention will now be described having reference to the accompanying Figures.Pallet

[0029] Referring now to the drawings, and more particularly to FIGS. 1 A to 3, there is shown generally a pallet 10, which has an upper horizontal load supporting surface 12 spaced apart from a lower horizontal ground-facing surface 14. The lower surface is configured with notches 16 for receiving the forks of a forklift or similar lifting device. Pallet 10 may be made of wood, plastic, or any other material or combination of materials, and is not restricted by dimensions or design. Pallet 10 may be a block pallet or a stringer pallet. Notches 16 may be on more than one side of pallet 10, for insertion under and lifting the pallet from any one of the sides of the pallet.

[0030] In some embodiments, pallet 10 comprises a base unit 18 that forms the lower horizontal ground-facing surface 14 and notches 16, and a deck unit 20 that forms the upper horizontal load supporting surface 12. In some embodiments, the base unit 18 defines one or more cut-outs 19 to minimize its weight. When the base unit 18 and deck unit 20 are assembled, they form the pallet 10. The deck unit 20 comprises deck boards or panels 21 positioned lengthwise, with adjacent boards 21 engaging each other by central, end, and / or corner joints 23. In some embodiments, the deck unit 20 further comprises removable boards or panels 25 for allowing access to the compartments 30 and components therein. The pallet 10 has a first side 22, a second side 24 perpendicular to the first side 22, a third side 26 opposite the first side 22 and a fourth side 28 opposite the second side 24. Pallet 10 may include one or more tracking devices 27 including, but not limited to, RFID tags, barcodes, or other such devices.Compartments

[0031] Disposed within pallet 10 on each of at least two sides of the pallet 10, preferably between surface 12 and surface 14, are compartments 30 that are each sized to accommodate a roll 34 of wrapping material 36 (FIG. 2B). The compartments 30 each extend substantially along the entire length of their respective side of the pallet 10. “Substantially” means that the compartment 30 extends from one end 29a to the other end 29b of a side of a pallet 10 (FIG. 3), or a minimum of 80%, 85%, 90% or 95% of the length of a side of the pallet 10. The length of the compartments 30 may be different; for example, if the pallet 10 is rectangular, one compartment 30 may be longer than another compartment 30.

[0032] In some embodiments and as shown in the FIGS, herein, one compartment 30 is disposed on the first side 22 and a second compartment 30 is disposed on the second side 24 perpendicular to the first side 22. In some embodiments, both compartments 30 are situated between surface 12 and surface 14. Each compartment 30 is sized to accommodate a roll 34 of load wrapping material 36 therein, and each compartment 30 extends substantially along the entire length of the side of the pallet 10. The compartments 30 may have different lengths. The compartments 30 form a protective housing for the rolls 34 of wrapping material 36, store the wrapping material 36 when not in use, and transport the wrapping material 36 together with the pallet 10.

[0033] In some embodiments shown in the FIGS, herein, the rolls 34 of wrapping material 36 are in a compartment 30 that is formed by assembly of the base unit 18 and the deck unit 20 of the pallet 10 together, that is, when the deck unit 20 is positioned over the base unit 18 and attached thereto. The compartments 30 are positioned so as not to interfere with the forks of a forklift or pallet jack when these are used to lift and move the pallet 10.

[0034] Other arrangements for the compartments 30 are included herein. In some embodiments, the compartments 30 may be positioned above the upper horizontal load supporting surface 12 or below the lower horizontal ground-facing surface 14, rather than between these surfaces 12, 14. In some embodiments, the compartments 30 may not have four straight sides arranged as a square in cross-section as depicted herein. Rather, the compartments 30 may have any number of sides and the sides may be curved, straight or another shape.

[0035] Further, the compartments 30 may not completely surround the roll 34 of the wrapping material 36, as shown herein. In some embodiments, the compartments 30 may have one open side, or may otherwise leave some part of the roll 34 exposed to the surrounding environment, while also protecting some portion of the roll 34 from the environment.

[0036] Each compartment 30 comprises a longitudinal slot 32 or other opening (FIG. 4C) through which the wrapping material 36 can be pulled, to unroll it from roll 34 and pull it around a load on the pallet 10. One roll 34 of wrapping material 36 is pulled around the load before a second roll 34 of wrapping material 36 is pulled around a load. Therefore, the wrapping materials 36 from two different rolls 34 at least partially overlap one another, typically over the top of the load. FIG. ID shows the wrapping material 36 from each of two rolls 34 pulled overthe deck unit 20 of a pallet 10. In some embodiments, the base unit 18 and the deck unit 20 cooperate to form the longitudinal slot 32 in the wall of the compartment 30.Wrapping material

[0037] The wrapping material 36 is an elongate flexible sheet, generally rectangular, that can be unrolled from compartment 30 and pulled over a load to secure the load to the pallet 10, and that can be rolled back into the compartment 30 when the load is to be removed from the pallet 10. The wrapping material 36 conforms to the shape of the load. One roll 34 of the wrapping material 36 is sized and shaped to circumvent two sides and the top of a load, appreciating that the size of the load (height and width) may vary. The wrapping material 36 may be formed of any known materials that are durable and resistant to tearing, puncturing and stretching, and preferably that can be cleaned and sterilized. It may be formed of plastic, cotton, burlap, fiberglass, nylon, rubber, or any combination thereof. It may or may not be a woven material (e.g., woven fabric, metal, plastic). It may be waterproof or water resistant and is preferably non- porous, UV resistant, fire-retardant and resistant to cracking when cold. Suitable materials include, but are not limited to, Cordura®, polyester, nylon and PVC vinyl. While depicted herein as a solid sheet of material, it need not be solid and may be a web or mesh. The wrapping material 36 is preferably a single piece but can be made of more than one piece. The wrapping material 36 may include written or graphic material, such as a logo, on its surface.

[0038] In some embodiments shown in the FIGS, herein, each roll 34 comprises wrapping material 36 that is wound around a rod member 52 of a roll assembly 50. In some embodiments, the rod member 52 may be an elongate rod or shaft. In some embodiments, the rod member 52 may be hollow or solid. In some embodiments, the rod member 52 may be of any suitable shape in cross section (e.g., circular or square) and material (e.g., metal, composite, wood).

[0039] As mentioned, the wrapping material 36 is a sheet of material wound around rod member 52. One end of the wrapping material 36 is attached to the rod member 52, and the opposite end of the wrapping material 36 is not (herein the “free” end).

[0040] At the attached end, the wrapping material 36 is attached so that it does not become detached from the rod member 52 during ordinary use of the wrapping material 36. The attachment to rod member 52 may be reversible or irreversible. A reversible attachment has the advantage of enabling the removal of the wrapping material 36 from the rod member 52 when needed or desired, for example if it becomes damaged.

[0041] In some embodiments, the rod member 52 is a hollow tube with a longitudinal slot, through which one end of the wrapping material 36 can be inserted and held inside the tube by a retainer. In some embodiments, a hem may be formed at one end of the wrapping material 36, through which the rod member 52 may be inserted before it is attached to the pallet 10.

[0042] The end opposite the attached end of wrapping material 36 is free end 38, which is grasped to pull the wrapping material 36 out of the compartment 30, thereby unrolling it from the roll 34. While it is contemplated that the unrolling of the wrapping material 36 and wrapping of the load will be accomplished manually, it may also be done by a machine.

[0043] The system disclosed herein may also comprise a means of reversibly attaching or connecting wrapping material 36 to a pallet 10. For example, the free end 38 may comprise a means of reversibly attaching or connecting the free end 38 to the pallet 10. In some embodiments, connectors 40 (FIGS. 3, 4B-C) at the free end 38 may be adapted to releasably connect with a mating set of receivers 42 on the pallet 10, thereby holding the wrapping material 36 around the load on the pallet 10. In some embodiments, an elongated grab bracket 43 which extends substantially along the entire length of the roll 34 of the wrapping material 36 may be used to releasably grab the free end 38 (FIG. 8 A). In some embodiments, a plurality of strips of hook and loop fasteners (Velcro®) may be attached to the wrapping material 36 (e.g., at the free end 40) and inserted into a corresponding plurality of rings on the pallet 10 to secure the wrapping material 36. In some embodiments, a plurality of metal hooks or carabiners on the pallet 10 or wrapping material 36, that mate with a plurality of eyes on the wrapping material 36 or pallet 10, respectively, may secure the wrapping material 36.

[0044] Each rod member 52 extends substantially along the entire length of its respective compartment 30, and each roll 34 of wrapping material 36 extends substantially along the entire length of their respective rod member 52. “Substantially” means that a rod member 52 or roll 34 extends from end-to-end of a compartment 30 or rod member 52, respectively, or they extend a minimum of 80%, 85%, 90% or 95% of the length of the compartment 30 or rod member 52, respectively.

[0045] Since the wrapping material 36 is attached to the pallet 10 at the free end 38 and in the compartment 30, the wrapping material 36 secures not only the load to itself (e.g., for a load that is a plurality of items stacked on the pallet 10), but also the load to the pallet 10, thus preventing the load from separating from the pallet 10, for example if the load / pallet gets knocked over.

[0046] The system and method disclosed herein can easily accommodate loads of different sizes, as all that is required is to unroll more or less of the wrapping material 36 depending on the size of the load. Further, if only a part of a load is removed from the pallet 10, the wrapping material 36 can be reapplied and tightened to hold whatever remains of the load on the pallet 10.

[0047] While the embodiments herein show only two rolls 34 of wrapping material 36 on the pallet 10, one each on the first and second sides 22, 24, other embodiments contemplate up to two additional rolls 34, one each on the third and fourth sides 26 and / or 28. Four rolls 34 of wrapping material 36 will enable very high loads to be secured to the pallet 10, for example by not overlapping the rolls 34, or by overlapping them less than is shown in the FIGS, herein.Roll Assembly

[0048] Roll assembly 50 is disposed inside compartment 30 and comprises rod member 52 and rotating means (not shown) for rotating the rod member 52 so as to roll and unroll the wrapping material 36 around the rod member 52. Embodiments of rotating means include, but are not limited to, a lever that can be operated manually, a socket that can be operated for example by a cordless drill, or a motor that can be operated for example by a push button, or other.

[0049] The rod member 52 has a first end and a second end, each of which are attached to the pallet 10. In some embodiments, the rod member 52 may have end caps that help to attach it to sealed bearings that are mounted onto the pallet 10. In some embodiments, the rod member 52 comprises one or more ider end assemblies 53. In some embodiments, the rod member 52 may have an end bearing holder 55 attached at each of its first and second ends (FIG. 8B). The end bearing holder 55 comprises a plate 57 defining a top central opening 59 for accommodating a bearing 168 and spring retainer 172 therethrough, and a plurality of lower spaced apart apertures 61 for receiving suitable attachment means (e.g., screws, bolts, etc.) therethrough for attaching to the base unit 18. In some embodiments, the plate 57 may comprise a D-ring assembly 63 including a D-ring insert and D-ring for attaching a strap (e.g., a ratchet strap instead of single use banding) to secure the load to the pallet 10. In some embodiments, the strap comprises an adjustable rachet strap including a ratcheting mechanism. The ratchet strap may comprise a durable webbing strap, a ratchet buckle for tightening, and hooks or other hardware for attaching to the D-ring. The ratchet mechanism allows for tensioning and loosening of the ratchet strap, making it ideal for securing a load.

[0050] The rod member 52 is attached to the pallet 10 so that it can be rotated in two directions, namely a first direction to unroll the wrapping material 36, and a second direction to roll the wrapping material 36 onto the rod member 52. In some embodiments, two rod members 52 along the first and second sides 22, 24 are linked with a gear set and a coupling so that both rod members 52 rotate simultaneously to unroll and reroll their respective wrapping materials 36. Tightening the Wrapping Material

[0051] In some embodiments, the pallet 10 includes a tightening means 54 for cinching or tightening the wrapping material 36 around a load to prevent shifting of the load and / or loss of the load. The tightening means 54 may be a component of the roll assembly 50 and may cause the rod member 52 to rotate, thereby pulling the wrapping material 36 back around the rod member / roll of wrapping material 36. In some embodiments, the tightening means 54 is a gear assembly at one end of the rod member 52. In some embodiments, the gear assembly comprises a ratchet system including a gear and a pawl (FIGS. 5, 6, and 7A-C). The rod member 52 is turned to tighten the wrapping material 36 and engagement of the pawl in the gear prevents rotation of the rod member 52 in the other (unrolling) direction. Turning of the rod member 52 may be manual (e.g., by a crank or by a cordless drill that fits into a socket, mechanical (e.g., by a motor built into the roll assembly), or other. In some embodiments, the tightening means 54 may be a spring 74 that biases the rod member 52 circumferentially, causing it to pull loose wrapping material 36 back around the rod member / roll of wrapping material 36. The spring 74 may be in a housing that protects the spring 74 from damage. In some embodiments, the tightening means 54 is not part of the roll assembly 50. In some embodiments, a plurality of strips of hook and loop fasteners (Velcro®) may be attached to the wrapping material 36 (e.g., at the free end 38), and tightening may be accomplished by inserting these strips into corresponding loops on pallet 10 and pulling on the strips to tighten.Locking the Rotation

[0052] It may be desired to prevent unrolling of the wrapping material 36 from the roll 34 without application of a pulling force, or when otherwise not desired (e.g., when the pallet 10 is not in use). Additionally, after connectors 40 and receivers 42 are connected to one another, it may be desired to lock the rod member 52 to prevent the wrapping material 36 from loosening or unrolling further. Tightening of the wrapping material 36 may increase tension on the wrapping material 36 to the point that the connectors 40 and receivers 42 cannot be disengaged from oneanother until this tension is released. To these ends, the roll assembly 50 may further comprise a releasable locking device / means 56, 156 that locks and unlocks the rod member 52 to prevent or allow rotation of the rod member 52 in one or both directions (rolling or unrolling).

[0053] In some embodiments, the releasable locking device 56, 156 is a gear assembly comprising a pawl that can be engaged with, or disengaged from, the gear. In the “locked” position, the pawl is engaged with the gear teeth, thereby preventing rotation of the rod member 52 in a direction that unrolls the wrapping material 36. In the “unlocked” position, the pawl is disengaged from the gear teeth, thereby permitting rotation of the rod member 52 in both directions (rolling or unrolling). The pawl may be engaged and disengaged by pushing on a pair of push rods 58a, 58b or slide knobs 158a, 158b.

[0054] Re-rolling of the wrapping material 36 around rod member 52 and back into compartment 30 is accomplished by rotation of the rod member 52. This may involve manual rotation of the rod member 52 (e.g., using a crank or a cordless drill), mechanical rotation (e.g., using a motor), a built-in spring-loaded mechanism, or by other means.

[0055] The details of a first embodiment of the roll assembly 50 and its ends are shown in FIGS. 5-7C. One end comprises a ratchet housing assembly 60 housing the rachet 62 and pawl 64, and through which upper and lower push rods 58a, 58b extend. Adjacent the rachet housing assembly 60, a first bearing housing 66 encloses a plurality of bearings 68 and is seated on a first spring mount spacer 70. Adjacent the bearing housing 66, a spring retainer 72 supports a spring 74 mounted over threads 76. The other end of the roll assembly 50 comprises a spring drive 78 adjacent a second bearing housing 80 which encloses a plurality of bearings (not shown) and is seated on a second spring mount spacer 82. A rotary shaft 84 facilitates the rotation of the rod member 52.

[0056] The details of a second embodiment of the roll assembly 50 and its ends are shown in FIGS. 8A-C. One end comprises a ratchet housing assembly 160 comprising a base 184 and a lid 186 attachable to the base 184 by a plurality of corner tabs 188 and fasteners 189. The ratchet housing assembly 160 houses the rachet 162 and pawl 164 comprising a locking mechanism slider, and to which the upper and lower slider knobs 158a, 158b extend through a window 190 in the lid 186 to disengage the pawl 164 from the rachet 162 in the “unlocked” position permitting rotation of the rod member 52 in both directions (rolling or unrolling), or to engage the pawl 164 with the rachet 162 in the “locked” position preventing rotation of the rod member52 in a direction that unrolls the wrapping material 36. The base 184 defines a top central aperture 192 for accommodating a bearing (not shown) therein. A spring mount spacer 170 and spring retainer 172 supporting a spring 74 mounted over threads 76 are positioned external to the base 184. A slotted spring plunger 194 comprising a ball nose may be included for positioning, indexing, and locking the ratchet 162 and pawl 164. The slotted spring plunger 194 is a type of spring-loaded mechanism having a ball at the end of a spring-loaded plunger, which can be depressed and then released to return to its extended position. The slotted head allows for easy installation and adjustment using a screwdriver.Methods

[0057] In a loading operation, the pallet 10 is first stacked with a load. A first wrapping material 36 in a first compartment 30 at a first side of the pallet (e.g., side 22) is then unrolled from its stored condition by pulling on its free end 38 and, if needed, after releasing the locking device 56. The first wrapping material 36 is pulled out the first compartment 30 over the stacked items and its free end 38 is releasably connected to the pallet 10 via the connectors 40 and receivers 42, or the grab bracket 43. This process is repeated with a second wrapping material 36 in a second compartment 30 at a second side (e.g., side 24) of the pallet 10. Both the first and second wrapping materials 36 may thereafter be tightened about the load, and the locking devices 56, 156 may be actuated (locked).

[0058] In an unloading operation, and if needed, tension on the first and second wrapping materials 36 from the tightening operations may be relieved by releasing the locking device 56, 156. The free ends 38 of each of the wrapping materials 36 are detached from the pallet 10. The second wrapping material 36 is rolled into the second compartment 30 of the second side 24, followed by the rerolling of the first wrapping material 36 into the first compartment 30 of the first side 22. The pallet 10 may then be unloaded after which it is ready immediately for re-use.

[0059] While the pallet and method have been described in conjunction with the disclosed embodiments which are set forth in detail, it should be understood that this is by illustration only and the disclosure is not intended to be limited to these embodiments. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents which will become apparent to those skilled in the art in view of this disclosure.

Claims

WHAT IS CLAIMED IS:

1. A pallet compri sing : a) an upper load-bearing surface and a lower ground-facing surface; b) a first side having a first compartment, wherein the first compartment extends substantially along the entire length of the first side; c) a second side perpendicular to the first side, having a second compartment, wherein the second compartment extends substantially along the entire length of the second side; d) a first roll of pallet wrapping material disposed in the first compartment substantially along the entire length of the first compartment; e) a second roll of pallet wrapping material disposed in the second compartment substantially along the entire length of the second compartment; f) a first opening in the first compartment, the first opening sized to enable unrolling of the first wrapping material from the first roll by pulling on a free end of the first wrapping material; g) a second opening in the second compartment, the second opening sized to enable unrolling of the second wrapping material from the second roll by pulling on a free end of the second wrapping material; and h) means for securing the free end of the first wrapping material and the free end of the second wrapping material to the pallet.

2. The pallet of claim 1, wherein the upper load-bearing surface is formed by a deck unit comprising a plurality of adjoining boards including at least two boards removably covering the first and second compartments.

3. The pallet of claim 2, wherein the lower ground-facing surface is formed by a base unit comprising one or more cut-outs for reducing weight and one or more notches for receiving and accommodating a lifting device.

4. The pallet of claim 3, wherein the deck unit and the base unit cooperate to form the first compartment, the second compartment, the first opening, and the second opening.

5. The pallet of claim 1, wherein the first roll comprises the first wrapping material wound around a first rod member of a first roll assembly, the first rod member comprising an elongate shaft and first and second ends attachable within the first compartment by attachment means; andwherein the second roll comprises the second wrapping material wound around a second rod member of a second roll assembly, the second rod member comprising an elongate shaft and first and second ends attachable within the second compartment by attachment means.

6. The pallet of claim 5, wherein the first roll assembly further comprises first rotating means for rotating the first rod member to unroll and reroll the first wrapping material around the first rod member; and wherein the second roll assembly further comprises second rotating means for rotating the second rod member to unroll and reroll the second wrapping material around the second rod member.

7. The pallet of claim 6, wherein the first and second rod members are linked with a gear set and a coupling to enable simultaneous rotation of the first and second rod members to unroll and reroll the first and second wrapping materials.

8. The pallet of claim 6, further comprising tightening means for rerolling the first and second wrapping materials around the first and second rod members, the tightening means being selected from a gear assembly, a spring, or hook and loop fasteners and corresponding rings.

9. The pallet of claim 6, further comprising releasable locking means for locking and unlocking the first and second rod members to prevent or allow rotation thereof.

10. The pallet of claim 9, wherein the releasable locking means comprises a gear assembly, the gear assembly comprising a pawl for engagement with a gear in a locked position preventing rotation, and for disengagement with the gear in an unlocked position allowing rotation.

11. The pallet of claim 10, wherein the releasable locking means comprises a housing assembly housing a ratchet and locking mechanism slider actuated by a pair of slider knobs.

12. The pallet of claim 1, wherein the means for securing the free end of the first wrapping material and the free end of the second wrapping material to the pallet are selected from connectors releasably connectable to receivers; a grab bracket; strips of hook and loop fasteners insertable into corresponding rings; or a plurality of metal hooks or carabiners releasably connectable to eyes.

13. The pallet of claim 1, being formed of wood or plastic.

14. The pallet of claim 1, wherein the first and second wrapping materials are formed of plastic, cotton, burlap, fiberglass, nylon, rubber, or any combination thereof, the first and second wrapping materials being reusable.

15. The pallet of claim 1, further comprising one or more tracking devices.

16. A method of securing a load to the top of a pallet, the method comprising: a) stacking a load onto a pallet; b) unrolling a first wrapping material from a first roll of pallet wrapping material that is attached to a first side of the pallet by pulling on a free end of the first wrapping material; c) covering two sides of the load and the top of the load with the first wrapping material; d) securing the free end of the first wrapping material to the pallet; e) unrolling a second wrapping material from a second roll of pallet wrapping material that is attached to a second side of the pallet by pulling on a free end of the second wrapping material; f) covering two sides of the load and the top of the load with the second wrapping material; and g) securing the free end of the second wrapping material to the pallet; wherein the first roll of wrapping material extends substantially along the entire first side of the pallet, and wherein the second roll of wrapping material extends substantially along the entire second side of the pallet.

17. The method of claim 16, further comprising tightening the first and second wrapping materials about the load using tightening means.

18. The method of claim 17, further comprising actuating locking means to prevent further unrolling of the first and second wrapping materials from the first and second rolls.

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