Abstract:
A pallet guard includes a plurality of modular pallet guard sections. Each pallet guard section comprises a connecting piece and a wall. The connecting pieces are adjustable. The walls are matable with another pallet guard section so that the pallet guard is adjustable to accommodate varying size pallets and/or spill-over merchandise on the pallet. Each connecting piece may be moveable between a first position, wherein the connecting piece is straight, and a second angled position where the pallet connecting piece forms a corner.

Description:
CROSS-REFERENCE RELATED APPLICATIONS 
     This application claims priority to and incorporates by reference provisional application No. 60/136,168 filed May 27, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     The invention relates to a pallet guard and more particularly to an adjustable, modular pallet guard which can be easily installed and assembled. 
     Palletized goods are commonly displayed for sale to customers of a business establishment. Displaying goods for sale in this manner is a convenience for business establishment owners or operators as a large quantity of merchandise can easily be transported out of a stock area utilizing a pallet jack or fork lift and placed with discretion around a store without further handling or arranging of the merchandise. While this type of product merchandising is a convenience to store operators, it sometimes creates an unpleasant visual effect and poses dangers to its customers. 
     Pallets are customarily designed to receive two parallel spaced arms of a pallet jack or fork lift. These arms slip under a pallet having merchandise stacked or placed thereon. The average pallet design is about 5-6 inches from the floor surface on which the pallet rests so that the pallet can receive the arms of the jack. Pallets are often made of wood, although plastic pallets are also available. When merchandise is stored on a pallet, where the pallet is utilized as a platform to display merchandise, initially, only the sides (usually 5-6 inches high) of the pallet may be visible to customers. However, these pallets are generally dirty, often have splintered and sharp edges, and may protrude out under the merchandise causing a danger for customers to trip and fall. As customers remove merchandise from the pallet for purchase, the outer perimeter of the merchandise, starting from the top, is removed first as this merchandise is closer to the customer and more within the customer&#39;s reach. Remaining, unsold merchandise is left in the middle of the pallet leaving more of the outer edges of the pallet protruding into the walk path of a customer creating more of a hazard to trip and fall. Customers traversing a store frequently have a shopping cart or some other carrying means for transporting a desired item from its storage place to a check-out counter. Merchandise which is stored on a pallet can be easily damaged by these shopping carts coming in contact with the merchandise or the pallets can injure customers or damage other merchandise or carts. Further, the pallets and/or merchandise can be damaged by these shopping carts. 
     Although pallets themselves have a standard size, it is convenient for the size of a pallet guard to be adjustable. This is because merchandise stored on a pallet frequently extends beyond the footprint defined by the pallet. If a pallet guard is designed to merely encompass the pallet only, it will be difficult to install the pallet guard if the merchandise spills over the pallet. Further it will not be possible to install the pallet guard to non-standard pallets. Further, the pallet guard could not also protect merchandise that extends beyond the pallet. Additionally, it may be desirable to protect a plurality of pallets which are disposed adjacent to one another or even disposed in an array. For example, similar or identical or even different goods may be placed on multiple adjacent pallets and so it would be logical and aesthetically pleasing to provide a single guard for a plurality of pallets holding these goods. 
     Prior art devices, like that shown in U.S. Pat. No. 5,704,488, merely provide a temporary barrier for goods stored on a pallet when the pallet is being shipped from one location to another. This barrier is fixed in size and so cannot protect multiple pallets nor can it protect an irregularly shaped pallet or a pallet which has merchandise extending over the footprint of the pallet. 
     Thus, there exists a need in the art for a pallet guard. Such a pallet guard should be modular to provide protection for multiple pallets and adjustable to provide protection for an irregular shaped pallet or pallet with merchandise extending beyond the pallet&#39;s footprint. 
     SUMMARY OF THE INVENTION 
     A first aspect of the invention is a pallet guard including a plurality of pallet guard sections. Each pallet guard section comprises an insertion member; and a receiving member coupled to the insertion member. One of the insertion member and the receiving member provides a plurality of adjustable positions for the insertion member with respect to the receiving member so that a respective insertion member of a first pallet guard section and a respective receiving member of a second pallet guard section are engageable in a plurality of positions thereby defining a plurality of areas for the pallet guard. 
     In a distinctive feature of the first aspect, one of the insertion member and the receiving member is a wall portion and the other of the insertion member and the receiving member is a connecting piece. 
     In another distinctive feature of the first aspect, the connecting piece comprises a first corner portion and a second corner portion hingedly coupled to the first corner portion. The first and second corner portions are moveable among a plurality of positions with respect to one another including a substantially straight position where the first and second corner portions are substantially in line with respect to one another, and a position in which the two portions are disposed at an angle to one another. 
     Another aspect of the invention is a method of assembling a pallet guard. The method comprising the acts of coupling together a plurality of pallet guard sections and adjusting the size of the pallet guard. 
     Yet another aspect of the invention is a pallet guard including a plurality of pallet guard sections. Each pallet guard section comprises a wall portion and a connecting piece, the connecting piece including a first corner portion coupled to a second corner portion. The first and second corner portions are movable among a plurality of positions with respect to one another including a straight position where the first and second corner portions are substantially straight with respect to each other, and a position in which the two portions are disposed at an angle to one another. 
     Still yet another aspect of the invention is a modular pallet guard comprising a plurality of pallet guard sections coupled together wherein a first quantity of the pallet guard sections coupled together protects a single pallet and a second quantity of the pallet guard sections coupled together protects multiple pallets. 
     Another aspect of the invention is a combination of a pallet and pallet guard. The combination comprises a pallet guard extending around and protecting the pallet. 
     Yet another aspect of the invention is a pallet guard comprising a plurality of modular wall sections, the plurality of wall sections being coupleable together by connecting members, the wall sections having a height sufficient to guard at least edge portions of a pallet, the wall sections being coupleable together by the connecting members so that one pallet or a plurality of adjacent pallets can be protected by the pallet guard. Preferably, the pallet guard is adjustable so that if merchandise extends beyond the pallet, the pallet guard is adjustable to account for such a situation. 
     The above aspects, and other aspects of the invention, will become apparent upon review of the following disclosure and corresponding drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For the purpose of illustrating the invention there is shown in the drawings form which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
     FIG. 1 is a perspective view of a first embodiment of a pallet guard in accordance with the invention; 
     FIG. 2 is a perspective exploded view of the pallet guard of the first embodiment; 
     FIG. 3 is a perspective view of a pallet guard in accordance with a second embodiment of the invention when the pallet guard is used to protect multiple pallets; 
     FIG. 4 is a perspective exploded view of a pallet guard in accordance with the second embodiment of the invention; 
     FIG. 5 is a perspective view of a pallet guard in accordance with the second embodiment of the invention when the pallet guard is used to protect a single pallet; 
     FIG. 6 is a perspective view of a third embodiment of a pallet guard in accordance with the invention; 
     FIG. 7 is a perspective view detailing the assembly of a pallet guard section in accordance with the third embodiment; 
     FIG. 8 is a perspective view detailing the assembly of a pallet guard section in accordance with the third embodiment; 
     FIG. 9 is a perspective view showing an assembled pallet guard section in accordance with the third embodiment; 
     FIG. 10 is an enlarged perspective view showing detents of a corner piece of a pallet guard section in accordance with the third embodiment; 
     FIG. 11 is an elevated perspective view of a fourth embodiment of a pallet guard in accordance with the invention; and 
     FIG. 12 is a perspective view detailing the assembly of a pallet guard section in accordance with the fourth embodiment. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention provides for a safety guard to be installed around a pallet storing merchandise. Referring to FIG. 1, there is shown a first embodiment of a pallet guard  20  in accordance with the invention. Pallet guard  20  is comprised of a plurality of substantially identical, modular pallet guard sections  36 . Each pallet guard section  36  includes a wall section  22  coupled to one corner piece  24 . Wall sections  22  extend substantially vertically and perpendicularly from the floor and are preferably at least twice the height of a pallet (not explicitly shown but hidden behind the pallet guard) that pallet guard  20  is to protect. Pallet guard  20  also protects merchandise  26  stacked on the pallet and provides a smooth solid surface that protects customers from tripping and falling over the exposed pallet edges. Pallet guard  20  is preferably made of a molded extruded or blown plastic and may be manufactured in a variety of colors and can include advertising space  28  for messaging, such as sale information, on, for example, one of wall portions  22 . Although pallet guard  20  is preferably a plastic, it can be made of any other suitable material. 
     Pallet guard  20  can be simply assembled and arranged in various configurations to shield a pallet on at least one side or all sides. Referring now to FIG. 2, there is shown the method for assembling pallet guard  20 . Each corner piece  24  of pallet guard section  36  includes a cavity  30  extending. Cavity  30  is designed to receive a wall section  22  of another pallet guard section. Disposed within cavities  30  are detent tabs  32  extending from a wall defining cavity  30 , inwardly into a respective cavity  30 . Each wall section  22  includes a recess tab  34  having a plurality of recesses  38  therein. When a wall section  22  of a first pallet guard section  36  is inserted within a corresponding corner section of a second pallet guard section  36 , detent tab  32  of the corner section is received within a selected recess  38  thereby retaining the wall section in a selected position in the corner section. A plurality of recesses  38  are provided on recess arrangement  34  so that a side wall  22  can be adjusted within a corner piece  24  and thereby define a plurality of lengths of a side of pallet guard  20 . Thus, pallet guard  20  is available in a plurality of sizes and so can fit different sized pallets, a plurality of pallets, an irregularly shaped pallet, or a standard pallet which has merchandise extending farther than the footprint of the pallet. This variability is due to the adjustment provided by the sliding arrangement of wall  22  in corner piece  24  into fixed, discrete positions provided by engagement of detent tabs  32  with one of recesses  38 . Although the embodiments shows detent tabs  32  and recess arrangement  34 , these can be dispensed with, in which case, continuous, limited adjustment is provided merely by the sliding arrangement of wall  22  in corner piece  24 . 
     As stated above, pallet guard  20  is preferably comprised of a plurality of pallet guard sections  36 . In the example shown in FIG. 2, four pallet guard sections  36  are connected together in a square rectangle to produce pallet guard  20 . Each pallet guard section  36  includes a corner piece  24  integral with a corresponding wall section  22 . Clearly, corner sections  24  and wall sections  22  need not be integrally formed into pallet guard sections  36  as corner pieces  24  and wall sections  22  can be formed as separate pieces. 
     To disassemble pallet guard  20 , the appropriate detent tab  32  is simply pulled toward a corresponding wall section  22  thereby disengaging detent tab  32  from a recess  38 . A first pallet guard section  36  can now be disengaged from a second pallet guard section  36 . To allow for this functionality, corner pieces  24  must be long enough to provide sufficient distance between a wall section  22  and merchandise  26  or a pallet, so that a user&#39;s finger can be inserted therein to depress recess tab  36 . 
     Though corner pieces  24  are shown with a generally L-shaped cross-section, other configurations of corner pieces  24  are possible and can be used for different arrangements of pallets. For example, corner pieces  24  can have a T-shaped cross-section so that each corner piece has three cavities to receive three wall sections  22  including a wall section belonging to an adjacent pallet guard. Further, pallets can be arranged in an array and still benefit from the pallet guard of the invention. Corner pieces  24  may also have a cross-shaped cross section with four cavities so that corner pieces  24  can receive four wall sections. Further connecting pieces comprising straight pieces (instead of corner pieces) can be provided so that pallet guards can be arranged modularly in an array, for example, to protect a plurality of pallets arranged in a row. This will be clearer from a review of the second embodiment as described below. 
     FIGS. 3-5 show a second embodiment of a pallet guard in accordance with the invention. The second embodiment provides for greater flexibility and modularization, for example, and eliminates the need for a straight or connecting piece when the pallet guard is to protect several pallets disposed adjacent to one another. This is accomplished through the use of pallet guard sections  38 . As with the first embodiment, a plurality of substantially identical, modular, pallet guard sections  38  are coupled together to form a pallet guard  40 . 
     Referring to FIG. 3, each pallet guard section  38  is comprised of a wall section  42  that is preferably integral with a first corner portion  44  of corner piece  48 . First corner portion  44  is further hingedly coupled to a second corner portion  46  of corner piece  48 . Corner piece  48  thus may assume an infinite number of positions between a substantially straight position where first and second corner portions  44 ,  46  are in line or straight with respect to one another, and a position where first corner portion  44  and second corner portion  46  form a corner of pallet guard  40 . Each pallet guard section  38  is preferably molded in two parts and then may be permanently or removably joined at corner piece  48 , allowing for a one piece design. 
     Referring to FIG. 4, four pallet guard sections  38  can be combined to form a pallet guard  40  to protect a single pallet (not shown). Pallet guard  40  is assembled in the same manner as pallet guard  20  and, as with the first embodiment, the area covered by pallet guard  40  is adjustable. Each second corner portion  46  of pallet guard  40  includes a cavity  50 . Cavities  50  are designed to receive wall sections  42  of an adjacent pallet guard section  38 . Disposed within cavities  50  are detent tabs  52  extending from a wall defining cavity  50 , inwardly into a respective cavity  50 . Each wall section  42  includes a recess tab  54  having a plurality of recesses  56  therein. When a wall section  42  of a first pallet guard section  38  is slidably received within a corresponding second corner portion  46  of a second pallet guard section  38 , detent tab  52  of the second corner portion  46  mates with a selected recess  56  thereby retaining the wall section in a selected position within second corner portion. A plurality of recesses  56  are provided on recess arrangement  54  so that a side wall can be adjusted within a second corner portion and thereby define a plurality of lengths of a side of pallet guard  40 . Disassembly of pallet guard  40  is the same as disassembly of pallet guard  20  and so the description will be omitted for the sake of clarity. Further, as in the first embodiment, tabs  52  and recess arrangements  54  can be omitted, allowing for limited continuous adjustability. 
     Pallet guard sections  38  thus can be combined to form a square barrier having a limited adjustment range! for example, as small as 40″ square to as large as 58″ square or can be formed as an oblong design according to the dimensions of an irregularly sized pallet. 
     In FIG. 4, a single pallet is shown protected by pallet guard  40  and so each second corner portion  46  is at an angle with respect to a respective first corner portion  44  so that corner pieces  48  are in the shape of corners. Alternatively, some of second corner portions  46  can be retained straight or in line with respect to a corresponding first corner portion  44  as is shown at corner  48   a  in FIG. 3. A pallet guard section  38  having a corner piece disposed like piece  48   a  can be used to increase the size of pallet guard  40  to protect a plurality of pallets. Since first and second corner portions  44 ,  46  are hingedly connected, a user has the option of maintaining a straight profile between these two elements thereby facilitating lengthening of pallet guard  40  to accommodate several pallets disposed side-by-side, grouped pallets, or pallets otherwise arranged in multiple clusters. As shown in FIG. 3, pallet guard  40  can be adapted to protect two pallets holding two sets of merchandise  26   a  and  26   b.    
     Thus, in the second embodiment, a plurality of modular pallet guard sections  36  are combined together to form a single pallet guard  40 . As many pallet guard sections  36  arc used as is necessary to form pallet guard  40 . If the pallet guard is to protect a single pallet, four pallet guard sections  36 , for example, can be used. Fewer pallet guard sections can be used to form a pallet guard—for example, one or two. To expand pallet guard  40  to protect more pallets, second corner portion  46  is rotated to be unbent with respect to first corner portion  44  as is shown by corner pieces  48   a  in FIG.  3 . 
     Referring to FIGS. 6-10, there is shown a third embodiment of the invention. A pallet guard  60  is comprised of a plurality of substantially identical, modular pallet guard sections  62 . Each pallet guard section  62  is comprised of a wall  64  that is preferably integral with a first corner portion  66  of corner piece  74 . First corner portion  66  is coupled to a second corner portion  68 , as is shown most clearly in FIGS. 7 and 8. Corner piece  74  can be configured into a discrete number of positions including a straight position where first and second corner portions  66 ,  68  are substantially in line with respect to one another and a position where first and second corner portions  66 ,  68  form a corner. 
     Referring to FIGS. 7 and 8, first corner portion  66  includes a post  70  that is shaped to slidably fit, preferably snugly, into a recess  72  of second corner portion  68 . Clearly, the provision of the posts and recesses could be reversed so that second corner portion  68  includes the post and first corner portion  66  includes the recess. As can be seen in the figures, first and second corner portions  66 ,  68  can be oriented with respect to one another in one of three configurations. First and second corner portions  66 ,  68  can be in line with respect to each other as is shown in FIGS. 8 and 9 so that they form a 0° or 180° angle with respect to one another. Alternatively, first and second corner portions  66 ,  68  can be disposed perpendicularly to one another in either a 90° or 270° angle as is shown in FIG. 7, thus forming a corner. 
     Referring to FIGS. 6 and 10, there is shown the structure used in combining pallet guard sections  62 . Each second corner portion  68  includes a cavity  78  having a plurality of tabs  76  extending therein. Cavity  78  is effective to receive a wall section of an adjacent pallet guard section. As can be seen most clearly in FIG. 6, each wall section  64  includes a ridge  80  at a distal end thereof. When adjacent pallet guard sections are combined, the ridge  80  of a wall section  64  is pushed against a corresponding tab  76  of an adjacent pallet guard section. This pushing biases tab  76  toward a wall that defines cavity  78  to thereby allow wall portion  64  to be received inside of cavity  78  of second corner portion  68 . Once ridge  80  passes tab  76  inside cavity  78 , tab  76  resumes its original position thereby retaining wall portion  64  within cavity  78 . 
     Cavity  78  is designed so that once wall portion  64  is received within cavity  78 , wall portion  64  assumes a telescoping or sliding arrangement with respect to second corner portion  68 . That is, wall portion  64 , and so a side of the resulting pallet guard  60 , can have a continuous range of perimeter lengths (thus defining an infinite number of areas for pallet guard  60 ). Pallet guard  60  thus allows for a continuous adjustment of positions, as opposed to a discrete number of positions as in the first two illustrated embodiments. Wall portion  64  is still retained within cavity  78  through a tab and recess as with the previous embodiment. It should be made clear, however, that a recess tab could be provided on wall section  64 , as with the first two embodiments, thereby allowing for a discrete adjustment of positions as well. 
     Pallet guard  60 , as with the previous embodiments, can be used to protect a single pallet or multiple pallets. If a single pallet is to be protected, first corner portion  66  and second corner portion  68  can be arranged perpendicular to one another as is shown in FIG. 7, so that corner piece  74  forms a corner. In such an arrangement, for example, four pallet guard sections  62  can be used—though it should be clear that fewer pallet guard sections can be used—for example one or two. If two pallets are to be protected, six pallet guard sections  62  can be used, for example, where two pallet guard sections have first and second corner portions  66 ,  68  unbent with respect to one another as is shown in the corner pieces in FIGS. 8 and 9. 
     Referring to FIG. 11, there is shown a fourth embodiment of the invention. A pallet guard  90  in accordance with the fourth embodiment of the invention is comprised of a plurality of pallet guard sections  92 . Each pallet guard section  92  includes a wall section  94  that is preferably integral with a first corner portion  96  of a corner piece  100 . First corner portion  96  is coupled to a second corner portion  98  of a corner piece  100 , as is most clearly shown in FIG.  12 . 
     Referring to FIG. 12, first corner portion  96  includes two buttons  104  extending perpendicularly from a reduced height portion  102 . Buttons  104  can be substantially cylindrical with a tapered end surface to facilitate insertion into corresponding holes  108  of portion  98 . Second corner portion  98  includes a recess  106  having two button holes  108  which receive buttons  104  with a snug fit. First and second corner portions  96 ,  98  can be combined in line with respect to each other so that they form a 0° or 180° angle. Alternatively, first and second corner portions  96 ,  98  can be disposed perpendicularly to one another in either a 90° or 270° angle. Corner pieces  100 , made of first and second corner portions  96 ,  98 , thus are movable among a discrete plurality of positions and thus suitable to be used with an individual pallet or a plurality of adjacent pallets. 
     Referring to FIG. 11, there is shown the structure for combining pallet guard sections  92 . Each second corner portion  98  includes a cavity  110  having one or a plurality of tabs  112  extending therein. Cavity  110  is effective to receive a wall section of an adjacent pallet guard section. Each wall section  94  includes a ridge  114  at a distal end thereof. Wall sections  94  further preferably include a plurality of discontinuous rails  116  each having a plurality of reduced height portions or voids  118 . When adjacent pallet guard sections  92  are combined, a ridge  114  of a wall section  94  of a first pallet guard section  92  is pushed against a corresponding tab  112  of an adjacent pallet guard section  92 . This pushing biases tab  112  toward a wall defining cavity  110  to thereby allow wall portion  94  to be received inside of cavity  110  of second corner portion  98 . Once ridge  114  passes tab  112  inside cavity  110 , tab  112  resumes its original position thereby retaining wall portion  94  within cavity  110 . 
     Cavity  110  is designed so that once wall portion  94  is received within cavity  110 , wall portion  94  assumes a telescoping or sliding arrangement with respect to second corner portion  98 . Unlike the previous illustrated embodiment, pallet guard  90  allows for discrete positioning of wall portion  94  within cavity  110 . At a discrete plurality of positions of wall portion  94 , tabs  112  will engage with voids  118  of rails  116 . Thus, each wall portion  94  can assume a discrete plurality of lengths and so pallet guard  90  is adjustable to varying sized pallets. 
     Alternatively, instead of tabs  112  engaging in reduced height portions  118  of rails  116  to provide detents, a vertically extending strip  113  (shown in phantom) can be provided on a corner surface  94   a  which allows wall portion  94  to slide between strip  113  and corner surface  94   a  of wall portion  94 . This allows for detenting of strip  113  in reduced height portions  118 . Of course, as in the third embodiment, it is clear that the detents and recesses can be dispensed with, in which case, limited continuous adjustability is provided. 
     Pallet guard  90 , as with the previous embodiments, can be used to protect a single pallet or multiple pallets. If a single pallet is to be protected, first corner portions  96  and second corner portions  98  can be arranged perpendicular to one another as is shown in FIG. 12, so that corner pieces  100  form corners. In such an arrangement, for example, four pallet guard sections  92  can be used—though fewer pallet guard sections could be used, for example one or two. If two pallets are to be protected, six pallet guard sections  9 , for example, can be used where two pallet guard sections have first and second corner portions  96 ,  98  in line with respect to one another. Corner piece  100 , made of corner portions  96 ,  98 , thus is movable among a discrete plurality of positions. 
     In the embodiments shown above, all of the pallet guard section modules are interlocking and interchangeable and can even be interchanged between different embodiments. The corresponding pallet guards do not require tools to assemble or disassemble. The components of the pallet guards can be formed from any suitable material, but preferably are formed from a molded plastic such as polypropylene, polystyrene, polyethylene or any other suitable plastic. 
     Although each wall portion is shown to be inserted into a void of a corresponding corner portion, it is evident that each corner portion could be inserted into a corresponding void in a wall portion. Thus, each wall portion can be viewed as either an insertion member or a receiving member. Similarly, each corner portion can be viewed as either a corresponding receiving member or an insertion member. 
     Although all of the wall portions are shown as being straight and unbent, clearly the wall portions can be bent or even curved without departing from the scope or spirit of the invention. 
     Thus by providing modular pallet guard sections, a pallet guard can be created of a desired size to accommodate and protect multiple pallets. By combining pallet guard sections using telescoping sections, the length of each wall of the pallet guard, and the corresponding area or footprint of the pallet guard, can be adjusted for irregular shaped pallets or for pallets having merchandise extending beyond the footprint of the pallet. 
     While preferred embodiments of the invention have been disclosed, various modes of carrying out the principles disclosed herein are contemplated as being within the scope of the following claims. Therefore, it is understood that the scope of the invention is not to be limited except as otherwise set forth in the claims.