Abstract:
A new pallet rail that is light weight, strong and environmentally friendly is part of an alternative modular pallet assembly. The rail includes a recessed portion with projections extending thereinto. A method of making the pallet rails and assembly is also disclosed.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to a pallet rail for a shipping pallet, a shipping pallet, and, in particular, a pallet rail that is light weight, has a recessed portion with projections extending in the recessed portion and a shipping pallet using the pallet rail. 
         [0003]    2. Technical Background 
         [0004]    Traditionally, pallets have been made of wood planks nailed together. In one common structure, a series of parallel upper wood planks are nailed to the top of three transversely extending, parallel, and equally-spaced wood support planks. Similarly, a series of parallel lower wood planks are nailed to the bottom of the three support planks. The tines of forklifts and/or pallet jacks can slide under the upper planks in the two parallel channels formed by the three spaced support planks. The forklift or pallet jack can then raise its tines, which lifts the pallet and anything mounted on it. While such pallets have been used for decades, they suffer from a surprising number of deficiencies. 
         [0005]    One is that the wood pallets require treating the wood. These requirements for the treatment of wood pallets have made the use of such wood pallets disadvantageous for many reasons, including increased cost and manufacturing complexity. However, it should be noted that since plastics and paper/corrugated packaging materials are inherently bug-proof, the regulations apply only to international shipments involving wood packaging materials. Upon inspection for export, any wood pallet found not to be in compliance with the rules would be destroyed, forcing goods to be re-palletized onto an approved pallet, or fumigated on site—all at the expense of the shipper. 
         [0006]    Another deficiency of wood pallets relates to environmental concerns. One third of US landfills will not take pallets, and others charge fees for taking pallets. Most pallets are eventually abandoned, left to pile up as a dangerous nuisance. 
         [0007]    These issues are not of great concern with plastics and paper/corrugated packaging materials, as pallets made of these materials are recyclable. It is worth noting that recyclable, paper-based pallets are already favored for export to environmentally concerned countries, such as the various EU members. 
         [0008]    A further deficiency of wood pallets revolves around the effect of their weight on a whole range of issues, such as added transportation costs, and handling difficulties for workers. The average weight of a 48″ by 40″ block style wood pallet with four way entry is approximately 45 lbs. The shipper must pay for the net weight of the pallet as part of the total transportation cost of the shipment, in all less-than-truckload (so-called “LTL”) volumes, as well as all domestic and international shipments by air. This added expense is significant. For example, the average domestic LTL trucking rate is $0.33 per lb. This means that it costs the shipper $14.85 to ship each pallet without any freight on it. With domestic air rates ranging from $0.60-$1.50 per lb. (depending on the service level), and export air rates at $1.00 per lb., the expense of shipping the pallet itself can have a profound impact on the total transportation cost. 
         [0009]    The handling of wood pallets by warehouse workers has been an issue for many years in terms of the repetitive lifting of heavy weights and injuries caused by splinters, exposed nails, and falling pallets. The issue of weight has grown as a concern since women are joining the traditionally male workforce in warehouses and shipping docks. OSHA has pressed U.S. industries to minimize human lifting weights to 45 lbs. It is common knowledge that the weight and condition of wood pallets have contributed to workmen&#39;s compensation claims in the transportation industry and has become a cost factor regarding their use. Government regulations and company work rules usually require that a damaged wood pallet be taken out of service and either repaired or replaced unless the damage is very minor. 
         [0010]    Still a further deficiency of wood pallets is the quality of the top load-bearing surface. Very frequently, the top surface is made of rough and uneven wood, which can cause damage to outer packaging, and sometimes to the goods themselves. While this might seem minor, in normal warehouse conditions where freight is handled roughly and quickly, damage claims can easily result. 
         [0011]    For decades, non-wood alternative pallet products, particularly paper-based/corrugated and plastic products, have been manufactured and widely distributed. Examples of such pallets are disclosed in U.S. Pat. Nos. 5,329,861; 5,595,125; 5,660,118; 5,784,971; 5,934,202; 6,357,364; and 6,612,207. These alternative products faced a number of obstacles that limited their ability to gain greater market share against wood pallets. One such obstacle is that generally pallets made from durable, recyclable, and reusable plastics, are regarded as far too expensive for single-use applications, and have only gained market share in closed loop transport systems where they can be recovered. Good plastic pallets generally cost between $75 and $90 each. Another obstacle has been that traditional paper-based pallets made from “homogeneous” materials such as Kraft paper honeycomb and corrugated paperboard have never enjoyed a significant price advantage over new wood pallets or a cost advantage when compared to used/reconditioned wood pallets. 
         [0012]    A further obstacle has been that traditional paper-based pallets generally cannot match many performance attributes inherent to wood pallets (especially relating to the deck support aspect of load-bearing). No currently offered paper pallet even claims to be strong enough to be used in unsupported warehouse racking systems. Wood pallets can be placed side by side in a warehouse rack loaded with freight, and stacked one on top of the other to a reasonable height limit. Such is not true of currently known paper-based pallets. 
         [0013]    Still a further obstacle facing paper-based pallets is that they have not been able to overcome their greatest perceived weakness; that they cannot be exposed to any water or be used in a wet environment. Consequently, unlike wood pallets, paper pallets cannot be stored outside, which is a common practice in many areas of this country. Although U.S. Pat. No. 5,359,861 does briefly mention that portions of the paper-based pallet could be coated with polyethylene, this process may not be very effective and typically is high in cost. 
         [0014]    What is desired, therefore, is a pallet system which is constructed from a wood alternative, which does not present a hazard of facilitating the migration of pests, which is not subject to the treatment requirements imposed by governmental agencies, which is relatively inexpensive to create and use, which does not pose great environmental concerns, which is lower in weight than wood pallets, which has a top surface which is not prone to damaging goods shipped thereon, which has a strength similar to that of wood pallets, and which is water resistant such that it can be used in humid or wet environments. 
       SUMMARY OF THE INVENTION 
       [0015]    Disclosed herein is a pallet rail to be used with a shipping pallet that includes an upper portion extending the length of the rail to support a shipping pallet deck, the upper portion having two upper surfaces and a lower surface, the lower surface connected to the two upper surfaces by upward extending portions, the lower surface and upward extending portions forming a recessed area between the two upper surfaces, the recessed area extending along at least a portion of the upper portion, a bottom surface, and two side portions extending between the upper portion and the bottom surface. 
         [0016]    In some embodiments, the two upper surfaces are separated by a third surface. 
         [0017]    In other embodiments, the pallet rail is a single piece of material that is folded along its length to create upper and lower surfaces and side portions. 
         [0018]    In another aspect, a shipping pallet is disclosed that includes a deck having an upper surface, an opposing lower surface, and a length, at least two elongated rail engagement members extending downwardly from the opposing lower surface and running along at least a portion of the length of the deck, at least two pallet rails attached to the lower surface of the deck, each of the pallet rails having two upper surfaces extending the length of the rail to support the deck and a recessed portion to receive a respective one of the at least two elongated rail engagement members, the recessed portion having a plurality of projections extending into the recessed portion, wherein the plurality of projections of each of the at least two pallet rails engage at least two elongated rail engagement members so as to cause the pallet rails to be attached to said deck. 
         [0019]    In another aspect, a method of manufacturing a shipping pallet is disclosed, the method includes a deck having an upper surface, an opposing lower surface, and a length, at least two elongated rail engagement members extending downwardly from the opposing lower surface and running along at least a portion of the length of the deck, and at least two pallet rails attached to the lower surface of the deck, each of the pallet rails having two upper surfaces extending the length of the rail to support the deck and a recessed portion to receive a respective one of the at least two elongated rail engagement members, the recessed portion having a plurality of projections extending into the recessed portion, wherein the plurality of projections of each of the at least two pallet rails engages at least two elongated rail engagement members so as to cause the pallet rails to be attached to said deck. 
         [0020]    Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, and the appended drawings. 
         [0021]    It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]      FIG. 1  is a top perspective view of a shipping pallet with the pallet rails according to one embodiment of the present invention; 
           [0023]      FIG. 2  is an exploded view of the shipping pallet and pallet rails according to the present invention; 
           [0024]      FIG. 3  is a perspective view of one of the pallet rails of  FIG. 1  according to one embodiment of the present invention; 
           [0025]      FIG. 4  is an enlarged perspective view of a portion of the pallet rail of  FIG. 3  illustrating the projections; 
           [0026]      FIG. 5  is a detail view of the projections on the pallet rails of  FIG. 1  according to one embodiment of the present invention; 
           [0027]      FIG. 6  is an end view of the pallet rail of  FIG. 3 ; 
           [0028]      FIG. 7  is a perspective view of the pallet rail of  FIG. 3  in a flat configuration prior to being folded; 
           [0029]      FIG. 8  is a perspective view of an elongated rail engagement member according to one embodiment of the present invention; 
           [0030]      FIG. 9  is an end view of the elongated rail engagement member of  FIG. 8 ; 
           [0031]      FIG. 10  is an end view of an alternative elongated rail engagement member according another embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0032]    Reference will now be made in detail to the present preferred embodiment(s) of the invention, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. 
         [0033]    Referring to  FIGS. 1 and 2 , a pallet assembly  10  according to one embodiment of the present invention is illustrated. The pallet assembly  10  preferably includes a deck  12  and three pallet rails  14 , each of the pallet rails  14  preferably being the same. The pallet assembly  10  also preferably includes three elongated rail engagement members  16  attached to the deck  12  and engage and secure the pallet rails  14  to the deck  12 . The pallet assembly  10  may also have more or fewer pallet rails  14  and elongated rail engagement members  16  than illustrated in  FIG. 1  and still fall within the scope of the present invention. The pallet assembly  10  may also have connecting rails  18 , three of which are illustrated in  FIGS. 1 and 2 . The connecting rails  18  are preferably connected to the pallet rails  14  by fasteners  20 , which may be screws, rivets, plugs, etc. 
         [0034]    The deck  12  preferably has an upper surface or skin  22 , a lower skin or surface  24  and a central portion  26 , which preferably has a corrugated, webbed, or honeycomb configuration. The deck  12  is preferably about 13 mm thick and is made from plastic, although any appropriate thickness and material may be used. The deck  12  is therefore weather and water resistant and is generally not subject to infestation by bugs or other detrimental creatures. 
         [0035]    The pallet rails  14  are preferably made of 18 gauge steel, although other thicknesses or similar materials of similar strength and abilities may be used. The pallet rails  14  are preferably 48″ long, 3″ wide, and 4″ in height, but again may be of any relevant size and shape for use as pallet rails. The pallet rail  14  preferably has an upper portion  30 , the upper portion  30  having two upper surfaces  32 , 34 , which are also preferably separated by a lower surface  36 . The lower surface  36  is connected to the two upper surfaces  32 , 34  by upward extending portions  38 , 40 , creating a recessed portion  42 . The two upper surfaces  32 , 34  are preferably in a first plane A, which is preferably parallel to and above the plane B in which the lower surface  36  lies, as best illustrated in  FIG. 6 . The pallet rail  14  also has a bottom surface  44 , which as illustrated in  FIGS. 4 and 6 , that may be formed from two portions  44 A and  44 B, joined at seam  46 . However, it is possible that the seam  46  be closer one corner or the other and not in the middle as illustrated in  FIG. 6 . Extending between the upper portion  30  and the bottom surface  44  are two side portions  48 , 50 . As can be seen from  FIGS. 4-6 , the pallet rail  14  is preferably formed from a single piece of steel that is folded at least four times, but as illustrated in the figures, is folded ten times (including the two folds to create the portions  44 A and  44 B). Without the portions  44 A and  44 B, eight folds would be necessary to fold the pallet rail  14  as illustrated in the figures. 
         [0036]    As best illustrated in  FIGS. 4 and 5 , the upward extending portions  38 , 40  preferably have a plurality of projections  60  that extend into the recessed portion  42  that engage the deck  12 , and more particularly the elongated rail engagement members  16  in the pallet assembly  10 . The plurality of projections  60  are preferably die-punched when the pallet rail  14  is still a flat piece of metal and before it is folded as illustrated in  FIG. 7 . The size and shape of the projections  60  are preferably symmetrical as illustrated in  FIG. 5 . That is, the projections  60  each are triangularly shaped projections with a point  62  that will engage the sides of the elongated rail engagement members  16  as explained in more detail below. However, it is also within the scope of the present invention that the projections  60  have any other relevant shape. The size and shape of the projections  60  that are punched out are not particularly important. However, the projections  60  preferably have a lower surface  64  that engages and prevents the elongated rail engagement members  16  from moving upward and out of the recessed portion  42 . 
         [0037]    The two side portions  48 , 50  also have features that assist in the operation of the pallet rail  14 . In particular, the features are included to provide strength to the pallet rail  14 . First, there are embossed areas  70  to provide structural strength to the pallet rail  14 . The embossed areas  70 , of which there are preferably nine along each side portion  48 , 50 , are also preferably stamped into the pallet rail  14  while it is flat and before it is folded. While nine embossed areas  70  are illustrated on each side portion  48 , 50 , there may be more or fewer, and they may extend substantially the entire height of the pallet rail  14  or only a lesser height. 
         [0038]    The two side portions  48 , 50  also preferably have openings  74 , of which there are preferably two to accommodate the tines of a fork lift. The openings  74  preferably have an inwardly extending flange  76  ( FIGS. 4 and 6 ) to provide structural strength to the opening  74  and the pallet rail  14 . 
         [0039]    As illustrated in  FIG. 7 , a flat piece of steel (or other appropriate material, including, for example, aluminum, stainless steel, etc.) is punched or cut to make the projections  50  and the openings  74 . The other structural elements, including embossed areas  70 , may also be added while the pallet rail  14  is flat. This also includes the addition of the flanges  76  to the openings  74 . The flat pallet rail  14  is then folded using appropriate dies so that, for example, when the flat pallet rail is folded to make the side portions  48 , 50  and the upward extending portions  38 , 40 , the projections  60  extend from the upward extending portions  38 , 40  and into the recessed portion  42  as illustrated in  FIG. 3 . The seam  46  could be welded, spot welded, clamped, strapped, or tied to provide further strength, but is not required. 
         [0040]    An elongated rail engagement member  16  is illustrated in  FIGS. 8 and 9 . The elongated rail engagement member  16  is preferably made from plastic, but could be constructed of any appropriate material including, for example, rubber or foam and may also be solid rather than being shaped. As described in more detail below, it is preferable that the elongated rail engagement member  16  can deform. The elongated rail engagement member  16  preferably runs across the entire lower surface  24  of the deck  12 , but could run along only a portion of the bottom surface  24  and still fall within the present invention. The elongated rail engagement member  16  has a center portion  80  that includes a bottom surface  82  and two vertical walls  84 . The two vertical walls  84  attach to extension members  86 . The elongated rail engagement member  16  engages the bottom surface  24  of the deck  12  by attaching the extension members  86  to the bottom surface  24 . The extension members  86  can be secured by any method, including, for example, adhesives, fasteners, welding, ultrasonically welding, etc. 
         [0041]    The bottom surface  82  preferably is configured with a point  88 , causing the bottom surface  82  to slope downward from the two vertical walls  84 . The elongated rail engagement member  16  is sized to fit within the recessed portion  42 . As the bottom surface  82  engages the lower surface  36  of the upper portion  30 , the configuration of the bottom surface  82  causes the the two vertical walls  84  to flex outward thereby ensuring engagement of the the two vertical walls  84  with the plurality of projections  60 . The lower surface  64  of the plurality of projections  60  engage the two vertical walls  84 , securing the rails  14  to the elongated rail engagement member  16  and deck  12 . 
         [0042]    An alternative embodiment of elongated rail engagement member  16 ′ is illustrated in  FIG. 10 . In this embodiment, elongated rail engagement member  16 ′ is similar to elongated rail engagement member  16 , but has a different configuration for the bottom surface  82 ′. Rather than having a point  88 , the elongated rail engagement member  16 ′ has a flat surface  88 ′ that functions as the point  88  functions. That is, when the elongated rail engagement member  16 ′ is inserted into the recessed portion  42  of the pallet rail  14 , the contact of the flat surface  88 ′ makes contact with the lower surface  36  of the upper portion  30 , causing the two vertical walls  84 ′ to flex outward. 
         [0043]    It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.