Abstract:
A stackable and nest-able pallet construction including a rectangular shaped insert incorporating structurally supporting and reinforcing members. The insert has a specified thickness encapsulated within a plasticized material and includes a plurality of downwardly extending support feet. Either of edge or corner defined mating locations are established between upper and lower surfaces, such that a second identically configured pallet is capable of being seated in supporting fashion upon a first pallet. To facilitate multiple (non-use) stackability, inter-attracting magnets can be disposed in upper and lower surface proximate locations of each identically configured pallet. The magnets may further include upper surface located and spring loaded magnets in combination with bottom surface recessed magnets of opposite polarity which, upon stacking atop an identically configured pallet, draws the upper spring supported magnet of a lower pallet into seating contact with an opposing and underside situated magnet associated with an upper pallet.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This Application claims the benefit of U.S. Provisional Application 61/973,559 filed on Apr. 1, 2014, the contents of which are incorporated herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention is directed to a composite stackable pallet construction for providing heavy duty support. More specifically, the present invention discloses a pallet with an insert or structural supporting blank which is sprayed or otherwise coated with a plastic or other polymer based recipe (including such as a proprietary formula and which may also include any particulate or aggregate additive for enhancing desired operational characteristics for varying environmental applications). Without limitation, the proprietary or other plasticized coating can also incorporate, without limitation, a fire/heat proof composite thermoset or composite thermoplastic material. 
     The three dimensional configured blank or insert can be constructed from any suitable material, not limited to a heavy duty paperboard corrugated material or galvanized insert. The pallet construction can be solid, however can also encompass interiorly extending open aperture locations, these further reducing the overall weight of the pallet without compromising its strength. 
     As will be further described, the pallet provides a number of useful features, including the incorporation of a GPS/RFID receiver for assisting in tracking of assets or cargo supported upon the pallet. Other features include any type of audio or visual feature, such as blinking lights which are activated by an integrated receiver/transmitter, this activating such as in response to a local transmitter used by warehouse personnel to assist in locating a desired pallet. 
     Yet additional features include edge or corner located magnets, typically spring loaded, which are positioned at both upper and lower facing surfaces of the pallet and which generate inter-attracting forces with successively stacked pallets, such as in a non-use storage configuration. Other features include downwardly projecting feet which configure pallet fork receiving locations for each pallet and which further mate with pallet upper surface seating recesses to further facilitate ease of stack-ability. Horizontally extending undercut channels formed along exterior corner edge locations of the pallet are also provided to assist in gripping a tautened, pull over edge of an industrial strength stretch wrap for restraining the cargo items supported upon the pallet. 
     BACKGROUND OF THE INVENTION 
     The prior art documents various examples of pallet constructions, such as which are capable of being stacked in multiple fashion when not in use. A first example of this is depicted by the pallet construction of Palmer, U.S. Pat. No. 8,356,562, and having a first portion and a second portion that may be arranged in a use or nesting positions to help facilitate more efficient storage of the portions. The portions may also include one or more magnets that may be used to help secure the portions in the use position and/or the nested positions. The portions may include one or more interlocking and/or engaging features that may be used to help secure the portions in the use position and/or the nested positions. If desired, the first and second portions may be sized and configured to be independently used as pallets. 
     A further example of a magnetic pallet is depicted in U.S. Pat. No. 4,361,822, to Adler, which teaches a plurality of individual, flexible polymer magnetic strips in a double layer thickness between metallic front and back enclosure plates to provide a substantially continuous magnetic field across both of front and back planar surfaces. Other examples drawn from the prior art include the all in one multifunction pallet of Liu et al, US 2011/0061572, which teaches a main part of the pallet, collapsible supporting legs, belts, joint shafts coupled by nuts, and RFID tags. 
     SUMMARY OF THE INVENTION 
     The present invention discloses a stackable and nest-able pallet construction including a rectangular shaped insert having a specified thickness and including a plurality of downwardly extending support feet. The insert may also include a plurality of structurally supporting and reinforcing members and which is encapsulated within a plasticized material not limited to at least one of a heat/fire thermosetting and a thermoplastic material. An aggregate material can be entrained within the plasticized material. 
     Additional features include a plurality of edge or corner defined mating locations established between upper and lower surfaces, such that a second identically configured pallet is capable of being seated in supporting fashion upon a first pallet. The insert may further be constructed of at least one of a galvanized steel, corrugated paperboard, or like rigid and structurally supporting material. 
     Other features include a receiver incorporated into the insert for providing at least one of tracking and identification of cargo supported upon the pallet. An antenna extending from the receiver can communicate with a remote transmitter. 
     To facilitate multiple (non-use) stack-ability, inter-attracting magnets can be disposed in upper and lower surface proximate locations of each identically configured pallet. The magnets may further include upper surface located and spring loaded magnets in combination with bottom surface recessed magnets of opposite polarity which, upon stacking atop an identically configured pallet, draws the upper spring supported magnet of a lower pallet into seating contact with an opposing and underside situated magnet associated with an upper pallet. 
     At least one audio-visual output can be incorporated into the insert for identifying the location of the pallet, upon receipt by said receiver of a location querying signal from the transmitter. The output further may also include a plurality of outer edge and/or corner located LED elements. 
     Other features include a plurality of stretch wrap gripping locations extending along exterior corner edges of the rectangular shaped insert. The gripping locations may further be configured as horizontally extending undercut channels formed along exterior corner edge locations of the pallet, these assisting in gripping a tautened, pull over edge of an industrial strength stretch wrap for restraining the cargo items supported upon the pallet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: 
         FIG. 1  is a perspective illustration of a pair of magnetically inter-attracting and stacked pallets according to one application of the present invention and also showing an upper stacked pallet with GPS/RFID receiver technology as well as audio/visual identification output; 
         FIG. 2  is an enlarged and partially cutaway corner location of the stacked pallets of  FIG. 1  and further showing the configuration of the inter-attracting magnets including an upper surface located and spring loaded magnet, in combination with a bottom surface fixed/recessed magnet of opposite polarity which, upon stacking atop an identically configured pallet, draws the upper spring supported magnet of the lower pallet into a recessed seating location in communication with the underside of the upper pallet; 
         FIG. 3  is a further corner underside perspective of a pallet and depicting a selected support foot with underside seating location for the receiving the spring loaded magnet of  FIG. 2 , in combination with the exterior corner edge extending channels for gripping pull-over tautened corners of the supporting cargo stretch wrap; 
         FIG. 4  is an exploded view in perspective of a pair of pallets similar to as illustrated in  FIG. 1  and further depicting an alternate construction of a plasticized spray coated pallet blank or insert in combination with upper pallet surface distributed seating recesses arranged in a pattern alignment with opposite bottom footprints associated with the downwardly extending support feet, such acting in combination with the magnetic inter-attraction features for further assisting in preventing lateral or other directed unseating of the magnetically stacked pallets; and 
         FIG. 5  is an illustration similar to that previously presented in  FIG. 2  of an enlarged and partially cutaway corner location of the separated pallets of  FIG. 4  and further showing recessed support feet locations associated with the upper surfaces of the pallets as well as a further configuration of inter-attracting magnets including an upper surface aligned magnet in combination with a bottom surface aligned magnet of opposite polarity which, upon stacking atop an identically configured pallet, creates an inter-attracting magnetic bond. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , a perspective illustration is provided of a pair of magnetically inter-attracting and stacked pallets, see generally at  10  and  12 , according to one application of the present invention. As previously described, the stackable pallet construction is designed so as to provide heavy duty support of items located thereupon and exhibits, according to the selected variant, a structural spine or insert (such as a heavy duty paperboard corrugated material or galvanized insert) which operates to greatly enhance the strength of the pallet assembly in supporting heavier loads set thereupon. 
     As will also be further described in detail, the manner of constructing the structural pallet article can vary greatly and can, in a most simplified construction, incorporate a sprayable or otherwise coat-able plasticized or polymer material, such including any known or proprietary blend and which can also include any specific additive (such as an aggregate or particulate) which enhances certain operational characteristics best suited for given environmental applications. For purposes of the present description, the composition and techniques surrounding the application of a plastic spray material contemplate such as any type of polystyrene, polyurethane or other material which can be spray applied or flowed over the exposed surfaces of the substratum material in such a way as to maintain it structural integrity while also delivering long term environmental protection. 
     Without limitation, the term plasticized coating can apply to any type of water-based polymer providing barrier and functional coatings, such as may further incorporate water-based surface modifiers, additives and polymers for numerous industries including wood care, industrial coatings, inks, fibers, composites, and construction products. In other non-limiting applications, the underlying blank or insert can be produced such as by placing within a mold cavity, or other manufacturing medium associated with the creation of the pallet article, and about which is injection molded or otherwise formed a fire/heat proof composite thermoset or composite thermoplastic material. 
     As will be further described, the completed pallet article can be solid, however can also encompass interiorly extending open apertured locations, recesses or other configurations, these further reducing the overall weight of the pallet without compromising its strength. As will be additionally described with reference to  FIGS. 1-5 , the underside of each pallet can further exhibit linear width and/or length extending recesses, and which are designed to seat inserting forks associated with a conventional forklift machine. 
     Referring again to  FIG. 1 , and as best shown with reference to upper located pallet  12 , each insert or blank exhibits a generally three dimensional rectangular shaped body, at  14 , from an underside of which projects along each interconnected side a plurality of intermediate side (e.g. at  16 ) and corner (e.g. at  18  and  20 ) located and downwardly extending support feet. An additional intermediate/middle support foot is also provided but is hidden from view in  FIG. 1 . As previously described, the construction of the pallet and support feet is such that intermediate apertures or recesses are defined as shown in relation to the configured underside of the pallet  12  for facilitating insertion of lift forks for elevating and transporting the pallet(s) in individual or multiple stacked fashion. 
     As further shown, the structural supporting insert can include cross extending or other spinal supporting members  22  and  24 , these arranged in a grid shape and which are bounded by edge extending members  26 ,  28 ,  30  and  32  in order to achieve a generally rectangular shape. The reinforcing grid components associate with the insert body depict sub-portions of the insert (see likewise rectangular shaped subset portions at  25 ,  27 ,  29  and  31  of the molded material associated with upper selected pallet  12 ). Without limitation, the body  10  can be constructed of a single and heavy duty molded material within which are embedded the structural supporting cross wise grid members  22  and  24 . Although not shown, it is also envisioned that the individual portions  25 ,  27 ,  29  and  31  can be affixed or seated within recessed locations defined by the insert grid  22 / 24  and outer perimeter extending sides  26 / 28 / 30 / 32 , as well as supported in other ways which maintain the load bearing and structural supporting integrity of the assembly. 
     A plasticized coating, such as representative of that previously described, is partially depicted in  FIG. 1  at  34  applied upon an upper corner portion of selected pallet  14 . It is again understood that substantially the entire pallet can be sprayed or otherwise coated with the plastic polymer, such encapsulating all of the pallet components with the exception of the LED (light emitting diode) or other visual identifying features associate with the pallet and as depicted at  36  and  38  with regard to corresponding side edges  26  and  32  which are visible in  FIG. 1 . 
     As previously described, each pallet can include a built-in receiver/transmitter, see at  40  for upper pallet  12 , and which is communicated, via one or more extending antennas  42 ,  44 ,  46  and  48 , by a remote (typically location proximate) transmitter, such in one non-limiting variant being a hand-held device employed by warehouse personnel for locating a specific pallet. It is further envisioned and understood that any suitable audio visual structure can be incorporated into the pallet architecture (such as including any piezo type audio emitter shown at  45  and  47  which can be provided along with or in substitution to the LED emitter diodes  36  and  38  and which can operate in combination with a portable processor component embedded or otherwise affixed to such as a recessed pallet underside location), this in order to enhance its article tracking/identification protocols. Such can further include providing illuminating types of components with different color or flashing patterns for identifying certain types of cargo, as well as potentially combining the piezo style emitter for providing an audial output or chirp along with the visual output, one advantage of which being the ability to identify such as an interiorly stacked or like positioned pallet in which the LED or other visual output locations may be partially or entirely obscured. 
     As further best depicted in  FIG. 1  by upper stacked pallet  12 , associated global positioning (GPS) or radio frequency identification (RFID) receiver technology can be utilized with the functionality built into the pallet for assisting in tracking and cataloging the cargo identified with the selected pallet(s). Without limitation, such external functionality can incorporate suitable processor and memory features for tracking in real time the location and disposition of various cargo or inventory items associated with a given pallet, such further being associated with JIT (just in time) inventory applications in which a premium is placed on the ability to track and inventory multiple cargo/pallets in remote electronic and real time fashion. 
     Proceeding to  FIG. 2 , an enlarged and partially cutaway corner location is depicted of the stacked pallets  10  and  12  of  FIG. 1  and further showing one non-limiting configuration of inter-attracting magnets for providing enhanced stack-ability of multiple pallets, such as during non-use applications not limited to storage or transport. In the example illustration, the selected corner located support foot  20  of the upper pallet  12  includes an upper corner surface located and spring loaded magnet  50 , this supported within a pocket or recess  52  defined in the upper corner with a bottom  54 , upon which a coil spring  56  secures the magnet  50  in a vertically displaceable manner. 
     In combination, each pallet  10  and  12  also includes a bottom surface fixed/recessed magnet  57  of opposite polarity with respect to the upper located magnet  50 . As further shown, the magnet  57  is seated within an underside corner pocket  58 . Upon stacking upon an identically configured pallet  10 , the underside magnet  57  operates to upwardly draw the identically configured and upper spring supported and opposite polarity magnet  50  of the lower pallet  10  from a normal position, in which the magnet  50  is held down by the spring so that its upper surface is flush with the top surface of the pallet, to an elevated position in which the magnet  50  is upwardly displaced against the pulling bias of the spring  56  into an adhering engagement with the underside affixed magnet  57  of the upper pallet  12 . In this fashion, the pallets are inter-attracted in a fashion which further facilitates and maintains their multiple stack-ability as well as which limits the instances of unexpected lateral or shearing disengagement of the pallets. 
     Proceeding to  FIG. 3 , a further corner underside perspective is shown of pallet  12  and depicting a selected support foot  18  with underside seating location  60  and edge perimeter wall  61 , such as for the receiving the spring loaded magnet  50  of  FIG. 2  in raised and adhering contact with the underside surface communicating and embedded magnet  57 . Also shown are exterior corner edge extending channels  62  and  64 , such extending in a generally “L” and cross-sectionally rounded edge shape, the configuration of which is suitable for gripping pull-over tautened corners of an industrial grade cargo restraining and supporting stretch wrap (not shown), upon such being applied over the pallet supported cargo as is typically done in the art. Without limitation, the channels can be reconfigured as protuberances or can provide other surface profiling which is engineered to facilitate a shear gripping condition with the tautened applied edge of the associated wrap material. 
     Proceeding to  FIG. 4 , an exploded view is shown in perspective of a pair of pallets, generally at  66  and  66 , these being similar to those illustrated in  FIG. 1  such that identical or near-identical components will not be repetitively described. As seen, the pallets each further depict an alternate construction of a plasticized spray coated pallet blank or insert. 
     Also illustrated are upper pallet surface distributed seating recesses, each of these including a perimeter extending edge defining a recessed interior and which are referenced by corner surface recesses  70 ,  72 ,  74  and  76 , in combination with alternating and intermediate side extending surface recesses  78 ,  80 ,  82  and  84 . An intermediate or middle recess is further shown and  86  and, upon stacking one pallet ( 12 ) upon another pallet ( 10 ), are arranged in a pattern alignment with opposite bottom footprints associated with the downwardly extending support feet (see further as represented at  88 ,  90  and  92  for selected pallet  12 ), such acting in combination with the magnetic inter-attraction features previously described for further assisting in preventing lateral or other directed unseating of the magnetically stacked pallets. 
     Finally,  FIG. 5  is an illustration similar to that previously presented in  FIG. 2  of an enlarged and partially cutaway corner location of the separated pallets  66  and  68  of  FIG. 4  and further showing selected recessed support feet locations, at  76  and  84 , associated with the upper surfaces of the stackable pallets  66  and  68 , as well as a further configuration of inter-attracting magnets for assisting in maintaining the pallets in inter-attracting and stacked fashion. In the illustration provided, this variant of the magnets includes an upper surface aligned and corner positioned magnet  94  seated within a corner pocket  96  defined in the selected pallet  68 . In combination, a bottom surface aligned magnet  98  of opposite polarity is embedded within an underside aligning pocket  100  and which, upon stacking atop an identically configured pallet, creates an inter-attracting magnetic bond in the manner previously described. 
     Also envisioned is the possibility of reconfiguring the pallets in order to provide any desired mating and alternating surface configurations for effectively stacking the pallets in multiple fashion. As further shown in the cutaway of  FIG. 5 , the material construction of the pallets  66 / 68  can also include a unitary molded body (with or without the grid extending reinforcing members  22 / 24  depicted in  FIG. 1 ), as well as including other possible shapes and profiles. 
     Although not shown, additional interior or side edge extending pairs of magnets can be provided in order to modify the attraction forces between the pallets in the stacked configuration. Also, and although not shown, it is also understood that hold down straps and associated strap engagement locations can be integrated into any suitably configured pallet body, these being provided alternate or in combination with the features described herein and in order to better secure items supported thereupon. 
     Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.