Abstract:
A pallet assembly includes an upper deck and a plurality of supports extending downward from the upper deck. A cap is secured in front of at least one of the supports to protect the support. The cap may be formed of a material different from the support, such as a higher density, tougher or harder material without increasing the cost of the materials for the supports and deck.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to a pallet assembly. 
         [0002]    Pallets are often used to store and transport goods. Pallets maintain the goods at a distance above the floor such that they can readily be lifted and moved by a forklift. Plastic pallets are lighter and more durable than wooden pallets. 
         [0003]    Some pallets comprise upper and lower decks separated by a plurality of columns that maintain the space between the upper and lower decks. Other pallets include only an upper deck supported by a plurality of columns. In either case, forklift operators sometimes move the loaded and stacked pallets by pushing on one of columns with one of the fork tines of the forklift. This may eventually damage the outer wall of the column. The damage is usually cosmetic, not structural; however, the appearance of the damaged column may lead some to believe that the structure of the pallet has been compromised and that the pallet needs to be replaced prematurely. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides a pallet assembly including an upper deck and a plurality of supports extending downward from the upper deck. A cap is secured in front of at least one of the supports to protect the support. The cap may be formed of a material different from the support, such as a higher density, tougher or harder material, without increasing the cost of the materials for the supports and deck. Optionally, whether or not made of tougher material, the cap can be replaceable if damaged. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]    Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0006]      FIG. 1  is a perspective view of half of a pallet according to one embodiment of the present invention. 
           [0007]      FIG. 2  is an exploded view of the half of the pallet of  FIG. 1 . 
           [0008]      FIG. 3  is a front view of the cap of  FIG. 2 . 
           [0009]      FIG. 4  is a rear view of the cap. 
           [0010]      FIG. 5  is a top view of the cap. 
           [0011]      FIG. 6  is a side view of the cap. 
           [0012]      FIG. 7  is a top view of the center, end column portion of the bottom deck of  FIG. 1 . 
           [0013]      FIG. 8  is a top view of the center, end column portion of the bottom deck and the cap. 
           [0014]      FIG. 9  is a bottom view of the center, end column portion of the top deck. 
           [0015]      FIG. 10  is a bottom view of the center, end column portion of the top deck and the cap. 
           [0016]      FIG. 11  is a top view of the pallet of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0017]    A half perspective view of an example pallet  10  constructed according to the present invention is shown in  FIG. 1 . Although only half is shown for simplicity, it is understood that the other half would be similar. The pallet  10  includes an upper deck  12  spaced above a lower deck  14  by a plurality of supports or columns including corner columns  16 , side columns  18 , a center column  19  and end columns  20 . The upper deck  12  and the lower deck  14  in this example are each a single, integrally formed part, such as by injection molding polypropylene or other suitable material. Other methods such as rotomolding or thermoforming may also be used. 
         [0018]    A column cap  22  is separately formed of a higher density material, such as a higher density polymer such as a high molecular weight high density polyethylene, such that it is stiffer and tougher than the end column  20  (i.e. than the upper deck  12  and lower deck  14 ), which may be polypropylene or polyethylene. The column cap  22  may be injection molded (if polymer) or formed according to any suitable process. In the example shown, the column cap  22  is fitted in front of only the end column  20  (and the opposite end column  20 , not shown), as this is the column most often impacted by the tines of the forklift; however, additional column caps  22  could be fitted over any or all of the remaining columns as well. 
         [0019]      FIG. 2  is an exploded view of the pallet  10  of  FIG. 1 . The upper deck  12  includes a plurality of integrally molded upper column portions  16   a ,  18   a ,  19   a ,  20   a  that together with integrally molded lower column portions  16   b ,  18   b ,  19   b    20   b , form the corner columns  16 , side columns  18 , center column  19  and end columns  20 , respectively. The lower deck  14 , as shown in this example, may include a plurality of runners  30  that interconnect the plurality of lower column portions  16   b ,  18   b ,  19   b ,  20   b . The end column lower portion  20   b  includes a front wall  50  having gaps  52  on either side of the front wall  50  between the front wall  50  and each of a pair of pillars  54  that protrude outward relative to the front wall  50 . The lower column portions  16   b ,  18   b ,  19   b ,  20   b  each include snap-fit connectors  34  for securing to complementary connectors on the corresponding upper column portions. Numerous other known ways of connecting the upper and lower decks  12 ,  14  can be used, such as heat staking, vibration welding, etc. 
         [0020]      FIG. 3  is a front view of the column cap  22  of  FIG. 2 . The column cap  22  includes a generally flat front panel  38  and curved side walls  40 . A plurality of teeth or tabs  42  project from the upper edge and from the lower edge of the front panel  38 . 
         [0021]      FIG. 4  is a rear view of the column cap  22 . A pair of integrally-molded hooks  44  project rearward and then inward from outer edges of the front panel  38 . As shown in  FIG. 5 , the hooks  44  open inward toward one another. The curved side walls  40  project forward of the front panel  38  and open rearward. 
         [0022]    As shown in  FIG. 6 , the tabs  42  protrude upward and downward further than the curved side walls  40 . Also, the curved side walls  40  taper inward as they extend away from the front panel  38 . 
         [0023]      FIG. 7  is a top view of the end lower column portion  20   b  of the lower deck  14  (with the column cap  22  removed). The end lower column portion  20   b  includes a plurality of apertures  56   b  in front of the front wall  50  and between the pillars  54 . 
         [0024]    As shown in  FIG. 8 , to assemble the column cap  22  to the end lower column portion  20   b , the front panel  38  of the column cap  22  is slid down in front of the front wall  50  of the end lower column portion  20   b . The curved side walls  40  fit around the pillars  54 . The hooks  44  of the column cap  22  are slid down through the gaps  52  to interlock with the front wall  50  to retain the column cap  22  to the end lower column portion  20   b . The tabs  42  of the column cap  22  are received in the apertures  56   b  in front of the front wall  50  in the end lower column portion  20   b  to further interlock the column cap  22  with the end lower column portion  20   b.    
         [0025]      FIG. 9  is a bottom view of the end upper column portion  20   a  of the top deck  12 , with the column cap  22  removed. The upper column portion  20   a  also includes a short rib forming a pair of spaced apart pillars  54   a  (much shorter than the pillars  54   b  on the lower column portion  20   b ) and a front portion  51 . A plurality of spaced-apart apertures  56   a  are formed in front of the front portion  51 . As shown in  FIG. 10 , the curved side walls  40  of the column cap  22  fit around the pillars  54   a  and the tabs  42  interlock with the apertures  56   a  to retain the column cap  22 . When the upper deck  12  is assembled to the lower deck  14  ( FIG. 8 ), the tabs  42  are so received in the apertures  56   a.    
         [0026]      FIG. 11  is a top view of the entire assembled pallet  10 . As shown, the pallet  10  includes a similar opposite end column  20 , which would also have a column cap  22 . 
         [0027]    In use, a forklift operator could push the pallet  10  across the floor by placing a tine of the fork against the column cap  22  of the end column  20 . The tougher higher-density material of the column cap  22  prevents damage to the end column  20  without unnecessarily increasing the cost of materials for the entire pallet  10  or column  20 . In the event that the column cap  22  does receive damage, it can easily be replaced. 
         [0028]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers for steps in method claims are for ease of reference in dependent claims and do not signify a required sequence unless otherwise stated.