Abstract:
A configurable pallet that can be readily assembled to match the particular load requirements of an application. The pallet includes structural elongated platform members  10; 10 ′ used in different configurations with either leg members  30  or reinforcement structural beams  20 . Platform members  10 ′ include conical protuberances  14′; 16 ′ that are receivable within cooperating frustoconical openings  14; 16  or  14   a;    16   a  that keep the structural members in place and perpendicularly to each other, in addition to the use of fastening members. When reinforcement beams  20  are used, the structural integrity of the pallet is enhanced to reduce the stress/relaxation wear thereby preventing or minimizing the possibilities of disengagement. A diaphragm plate  225  is optionally used to enhance the structural stability of beam  20.

Description:
This application is a 35 USC 371 application of International PCT Patent Application No. PCT/CR2012/000003 filed on Sep. 17, 2012, the entire content is hereby incorporated by reference herein. 
     TECHNICAL FIELD 
     1. Field of the Invention 
     The present invention relates to cargo pallets, and more particularly, to such pallets that are configurable, repairable, recyclable and adjustable to different load capacities. 
     2. Background Art 
     Several pallets have been designed in the past. One of the related references corresponds to applicant&#39;s published PCT patent application number PCT/CR09/000001. Patent application discloses a manufacturing method and the configuration of structural members to construct recyclable lightweight pallets that have configurable load capacity for multiple applications. However, the present invention is a new pallet that incorporates innovations to create a more versatile and efficient pallet for a wider range of load capacities, and still compatible with cost effective manufacturing processes for its components. The differences between the invention claimed herein and the PCT patent application include the use of frustoconical protuberances along central beams that are inserted into corresponding frustoconical holes in platform members for ready anti-rotation engagement enhancing stability, and rigidity of the pallet. Platform members that are volumetric efficient placed on both the top and bottom sides of the pallet with non-slip rubber blocks that protrude out from both sides of the platform members to prevent sliding of the loads or slippage of the forklift forks. Central beams designed to provide a calibrated ability to match loads of different capacities delivering the best weight to capacity ratio for the present invention. The wide load capacity range meets most, if not all, applications with minimal inventory logistics and ready on site assembly and repair, if necessary. 
     U.S. Pat. No. 5,458,069 consists of a skid, or pallet, made with central rails and cross members or runners perpendicularly connected to the rails at the top and bottom of the rails. The cross members are connected to the rails through the rail posts that are inserted into corresponding runner openings to which the posts are welded. As another option of connecting such runners to the rails, the posts are threaded and the runners have corresponding openings to receive such threaded posts and to fasten them with threaded nuts that lock the runners onto the rails. The rails have flanges and reinforcing ribs along both sides of their webs; the rails have two channels at their bottom side to insert a forklift to manipulate them. 
     U.S. Pat. No. 6,837,170 B2 consists of a pallet made with central stringers and deck members or runners perpendicularly connected to the stringers at the top and bottom of the stringers. The deck members are connected to the stringers through grooves, locking buttons, and locking sockets that on the top and bottom sides of the stringers are used for interlocking themselves with the deck members. The stringers have flanges and reinforcing ribs along both sides of their webs; the stringers also have two channels at their bottom side to insert a forklift to manipulate them. 
     US 2008/0105168 A1 patent application relates to pallets formed by single-piece platforms, or as other options, by platforms made with a grid structure obtained by connecting several deck boards perpendicularly to each other. Such platforms or grid structures make up the superior and inferior pallet surfaces, which are separated by cylindrical or rectangular spacing legs, and they are connected by threaded means to join such platforms while maintaining the spacing legs between the two platforms. 
     Patent WO 97/17263 consists of a pallet made with single-piece platforms to form the superior and inferior surfaces of the pallet, separated, and connected with blocks with engaging means to join both platforms and form the pallet. 
     U.S. Pat. No. 6,352,039 consists of a pallet made of thermoplastic material, which is formed by interconnecting several members without using mechanical connections but instead using adhesives or thermal welding. 
     U.S. Pat. No. 5,337,681 consists of a plastic recyclable pallet made by perpendicularly interlocking slats and rails. 
     U.S. Pat. No. 4,843,976 consists of a plastic pallet formed by two single-piece platforms with flat surfaces and joined by cylindrical spacers with interlocking connecting features. 
     U.S. Pat. No. 4,597,338 also consists of a plastic pallet formed by two single-piece platforms with flat surfaces, but joined by rectangular spacers that interlock to the platforms to form the pallet. 
     Even though several pallets have been designed in the past, the applicant believes that none of them discloses a design of a repairable, recyclable, and reusable cargo pallet with a modular structure, configurable load capacity, and with non-slip rubber surfaces to prevent sliding of the cargo on the pallet and of the pallet on the ground, shelf, and forklift. Additionally, the present invention includes the use of elongated plate members mounted to the beams that can be used to selectively enhance the reinforcement of the beams. 
     Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention. 
     SUMMARY OF THE INVENTION 
     It is one of the main objects of the present invention to provide a volumetrically efficient pallet that can be configured, without requiring the use of specialized tools, to match the load capacity required for a given application. 
     It is another object of this present invention to provide such a pallet that is recyclable and resistant to the elements. 
     It is still another object of this present invention to provide such a pallet that can be stored and transported utilizing minimum space. 
     It is yet another object of this present invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness. 
     Further objects of the invention will be brought out in the following part of the specifications, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which: 
         FIG. 1  is an isometric view of one of the embodiments for the present invention using six platform members  10  for the top of pallet  1  and four platform members  10 ′ defining the bottom of the pallet, along with leg members  30  cooperatively mounted to members  10 ′ and distributed to keep the pallet  1  at a spaced apart and parallel relationship with respect to a resting surface. 
         FIG. 1A  is an elevational cross-sectional view taken along line  1 A in  FIG. 1 . 
         FIG. 2  represents an isometric view of one of the embodiments for the pallet incorporating the present invention having four beam members and five platform members  10  to define the top of the pallet and three platform members  10  defining its bottom. 
         FIG. 2A  shows an enlarged detail view of a portion of the pallet shown in  FIG. 2 . 
         FIG. 2B  represents an isometric view of another configuration for the pallet incorporating the present invention having three beams  20  and seven platform members  10  defining the top and three platform members  10  defining the bottom. This figure also shows a reinforcement diaphragm plate mounted against a lateral wall of a beam member  20  having the height of beam member  20 . 
         FIG. 2C  shows an enlarged isometric detail view of a portion of the pallet shown in  FIG. 2B . 
         FIG. 2D  shows an enlarged partial cross-sectional view, taken along cutting line  2 D in  FIG. 2B  of a portion of the pallet. 
         FIG. 2E  shows an enlarged partial cross-sectional view, taken along cutting line  2 E in  FIG. 2B  of a portion of the pallet. 
         FIG. 3  illustrates an isometric view of an embodiment for platform member  10 ′, showing the upperside with sequences of groups of three longitudinally disposed protrusions: two frustoconical and between them a cylindrical protrusion with a central through hole. 
         FIG. 3A  shows an isometric view of the underside of the platform member  10 ′ shown in  FIG. 3 . 
         FIG. 3B  shows a partial elevational view of platform member  10 ′ shown in  FIG. 3 . 
         FIG. 4  illustrates an isometric view of an embodiment for platform member  10 , showing the upperside. 
         FIG. 4A  shows an isometric view of the other (bottom) side of the platform member  10  shown in  FIG. 4 . 
         FIG. 4B  shows an isometric view of an anti-skid rubber block. 
         FIG. 5  is an end elevational side view of the pallet shown in  FIG. 2  with beam  20  extending longitudinally at front and platform members  10  seen from their ends. 
         FIG. 5A  is an end elevational side view of a pallet represented in  FIG. 2B  showing the central beam extending longitudinally with end views of seven platform members  10  defining the top of the pallet and three platform members  10  defining the bottom. 
         FIG. 5B  is an enlarged detail view of a portion of the pallet shown in  FIG. 5A . 
         FIG. 5C  is an end elevational side view of the pallet shown in  FIG. 2  with beam  20  seen from the ends and platform members  10  extending longitudinally at the front. 
         FIG. 6  shows an elevational view of three different sets of fastening members used to connect the platform members to themselves and/or to the beam members. 
         FIG. 7  is an inclined view of a leg member  30  used in the present invention. 
         FIG. 7A  is an isometric view of the leg member  30  shown in  FIG. 7  showing the bottom of leg member  30 . 
         FIG. 8  is an isometric view of a beam member  20  to which reinforcement plates  225  are being added. 
         FIG. 8A  is a side elevational view of beam member  20  represented in  FIG. 8  showing three tubular sleeves  28  through which screw members  27  are passed and nuts  27 ′ mounted to the distal ends of screw members  27 . 
         FIG. 8B  is an enlarged detail view of an end of beam member  20  showing the position of tubular sleeve  28 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, where the present invention is generally referred to with numeral  1 , it can be observed that it basically includes structural elongated platform members  10  and  10 ′ used in different configurations with either leg members  30  or reinforcement structural beams  20 . The number and characteristics of these members allow a user to configure pallets that will efficiently match the load requirements for the application at hand while optimizing the logistics for transporting and storing the pallet components in a volumetric efficient manner. The components are all recyclable and repairable on site without requiring specialized tools. 
     As it can be seen in  FIG. 1 , one of the basic configurations utilizes platform members  10  and  10 ′ with leg members  30 , all removably mounted, to configure a pallet for relatively low load applications. The minimum number of platform members  10  needed are three with three platform members  10 ′. In  FIG. 1  a common configuration is shown with six members  10  defining the upperside of pallet  1  and four members  10 ′ defining the underside. Members  10  are kept at a parallel and spaced apart relationship with respect to each other. The same is true for members  10 ′. Members  10  and  10 ′ are perpendicularly disposed with respect to each other, as it can be best seen in  FIG. 1 . 
       FIG. 1A  is a partial elevational cross-section of a corner of pallet  1  represented in  FIG. 1 , taken along cutting line  1 A. It can be seen that this embodiment shows leg member  30  having a substantially frustoconical shape with tapered pins  34 ;  36  and cylindrical pin  38  at end  31  of leg member  30 . Through opening  37  centrally and longitudinally extends from pin  38 . The other end  32  includes drainage openings  33  to prevent the storage of water inside leg member  30 . One way for implementing leg member  30  is shown in  FIGS. 7 and 7A . A minimum of one pin, either  34  or  36 , is needed to prevent the rotation caused in normal use of the pallet. Screw member  72  is shown in  FIG. 1A  passing through central through opening  37 , washers  78  and mating with nut  75  tightening leg member  30  in place. Nut  75  is housed within counter base  35 . Screw member  72  provides a rigid core for leg member  30  while at the same time members  10  and  10 ′ are securely fastened. Pins  34  and  36  prevent any rotational movement that would tend to loosen the mechanical engagement of members  10 ,  10 ′, and  30 . Several fastening members generally referred to with numeral  70  are shown in  FIG. 6 . Depending on the use and characteristics of the elements being mounted together one or the other is used. 
       FIGS. 3 and 3A  shows the upperside and underside of platform member  10 ′. The upperside includes sets of three protrusions, in this embodiment, namely, frustoconical protrusions  14 ′;  16 ′ and cylindrical protrusion  15 ′, that are longitudinally aligned. One set is located, at a predetermined location, adjacent to end  11 ′ and another set is located adjacent to end  12 ′. Opposite to protrusions  14 ′;  16 ′ and  15 ′, as seen in  FIG. 3A , are holes  14   a ′;  16   a ′ and  15   a ′, respectively. 
     Platform members  10 , as shown in  FIG. 4 , extend longitudinally for a predetermined distance that is typically compatible with commercial cargo containers. One side, that is referred to as the upperside, is substantially flush with the exception of groups or sets of holes  14 ;  15 ;  16  that are transversally disposed at predetermined locations along member  10 . One set is located adjacent to end  11  and another set is located at end  12 . Holes  15  is a through cylindrical hole while holes  14  and  16  have frustroconical internal cavities to cooperatively receive cylindrical pin  15 ′ and frustoconical protrusions  14 ′ and  16 ′, respectively. The other side, referred to as the underside, has frustoconical holes  14   a ;  16   a  and cylindrical through hole  15   a , similar and opposite to holes  14 ;  16  and  15 , respectively. The former also cooperatively receive frustoconical protrusions  14 ′;  16 ′ and cylindrical protrusion  15 ′. 
     As discussed above, cylindrical through holes  15 ;  15   a  and  15   a ′ cooperatively align to permit screw  74  to pass through and through central opening  38  of leg member  30 . And this engagement is possible also if members  10  are flipped (one or more) to provide a substantially flush surface if desired. 
     Through opening  19  on the upperside of member  10  in  FIGS. 4 and 19   a  in  FIG. 4A , removably receives rubber block  18  to provide an anti-skid action on the upperside and underside of member  10 . Through openings are spaced apart to cover different areas of the pallet&#39;s top and bottom surface where the load lies and where the forklift engages. 
     As it can be seen in the design configuration shown in  FIG. 2 , a pallet  100  intended for larger loads can be configured using five platform members  10  to define the pallet&#39;s top and three platform members  10  to define the bottom. Between the top and bottom, four reinforcement beam members  20  are mounted perpendicularly with respect to members  10 . Members  10  at the top are coplanarly kept at a spaced apart and parallel relationship with respect to each other and the same is true for those defining the bottom of pallet  100 , when beam members  20  are used. The load enhancement introduced by beam member  20  also reduces the deflections created by stress/relaxation changes that cause the fastening members to become loose. 
     In  FIG. 2A , a detail view of portions of two members  10  a beam  20  are shown. The frustoconical protrusions  24  and  26  and cylindrical protrusions  25  of the latter engage a set of frustoconical holes  14 ; 16  and cylindrical through hole  15  of the former are not shown but an adjacent set of holes is seen where these members  10  and beam  20  could have also been mounted. These sets of frustoconical holes  14 ;  16  and cylindrical holes  15  along with corresponding frustoconical protrusions  24  and cylindrical protrusions  25  on beam  20  are cooperatively disposed along members  10  and beams  20  to provide the best structurally balanced possible configurations while permitting the use of forklifts to manipulate pallet  100 . 
     Another configuration is shown in  FIG. 2B  to provide a pallet  200  with larger load capacity. In this configuration seven platform members  10  and three platform members  10  are used at the top and bottom, respectively, of pallet  200 . A stronger and larger supporting surface is provided while keeping the same number of platform members  10  for the pallet&#39;s bottom. Only three beam members  20  are used. Beam members  20  are cooperatively spaced from each other to permit a forklift&#39;s forks to pass between beams  20 . A plate  225  is used to reinforce beams  20 . 
     In some applications, such as medical supplies loads, it is preferred to provide a substantially flush surface for the top of the pallet. For these applications, platform members  10  at the top, in  FIGS. 2 and 2B , can be flipped. 
     Beam members  20  have predetermined cooperative dimensions to permit the assembly of pallets compatible with the loads and transportation limitations. Typically, the dimensions are selected to be compatible with conventionally available containers. Beam members  20  include and upper wall  21  and a lower wall  22 , along with longitudinally extending lateral walls  23 ;  23 ′. Web  29  separates walls  21  from  22  and provides the necessary efficient (with minimum weight) rigidity to this reinforcement structural member. Upper wall  21  includes frustoconical pins  24  and  26  and cylindrical pins  25 , alternating each other, that are receivable within frustoconical holes  14   a ;  16   a  and cylindrical through holes  15   a , respectively. The engagement of the frustoconical pins  24  and  26  to holes  14   a  and  16   a  prevent rotational movements. The engagement of cylindrical pins  25  with cylindrical through holes  15   a  permit screw members  74  to pass through for fastening the two structural elements. 
     In  FIG. 8 , an alternate embodiment is shown where beam member  220  includes elongated reinforcement diaphragm plates  225  removably mounted to lateral walls  23  and  23 ′. Or, optionally, only one lateral wall  23  or  23 ′ is reinforced with one plate  225 . Sleeves  28  are mounted to web  29 , at predetermined locations, and receive therein screw members  74  that pass therethrough. Plates  225  provide a volumetrically efficient way to substantially enhance the load capacity of beam  20  minimizing their deflection and stress/relaxation effects that might end up loosening the pallet&#39;s structure. 
     In use, a user can readily assemble a pallet for the particular load capacity requirements of the application without being harnessed to a specific design that more than likely will exceed considerably the needs of the application. Then, if the pallet needs to be returned (in many instances the pallets are used one way only because of demand or other factors) then the different components are stored and transported in a volumetrically efficient manner. 
     INDUSTRIAL APPLICABILITY 
     It is apparent from the previous paragraphs that an improvement of the type for such a pallet is quite desirable for the efficient transportation of cargo, as well as the ability to repair the pallets from components that can be readily kept in inventory. The volumetric efficient storage of the units for transportation back to where the pallet was originally shipped from, also enhances the value of the present invention.