Abstract:
An apparatus, system, and method are disclosed for integrating the steps of securing and aligning a ramp to the pallet. A pallet mounting bracket secures to a pallet and mates with a corresponding ramp mounting bracket secured to a ramp. A pallet mounting bracket includes a registration receptacle that receives a registration member secured to the ramp mounting bracket in order to position the ramp with respect to the pallet. A driving member secured to the pallet mounting bracket engages a corresponding engagement portion on the ramp mounting bracket as the ramp is lowered into place next to the pallet. The driving member urges the engagement portion toward the pallet thereby urging a fastener secured to the ramp mounting bracket into engagement with a locking portion secured to the pallet mounting bracket thereby locking the ramp into position in alignment with the pallet.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     This application is a divisional application under 37 CFR 1.53(b) of and claiming priority to U.S. patent application Ser. No. 11/007,615 entitled “PALLET-RAMP COUPLING APPARATUS AND METHOD” and filed on Dec. 8, 2004 for Christopher M. Turner, which is incorporated herein by reference. The specification and drawings include no new matter. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates generally to an apparatus, system, and method for unloading pallets and more particularly to an apparatus, system, and method for coupling unloading ramps to pallets.  
         [0004]     2. Description of the Related Art  
         [0005]     Wooden and plastic pallets are ubiquitous in the shipping industry. Nearly every shipment of bulky items comes attached to a pallet. Typically the pallet provides a standard interface for forklift blades when lifting the cargo and pallet for transport. Pallets provide an additional benefit of having a standardized size, enabling goods loaded on pallets to be packed tightly together during shipping.  
         [0006]     Because pallets typically must provide some room for insertion of forklift blades, the upper surface of the pallet may be as much as seven inches above the ground. When the pallet and its cargo arrive at a final destination, the recipient must typically find some means to move the cargo the seven inches from the top of the pallet to the ground. Such an operation can be very problematic for bulky, delicate items such as large computer systems, of which pre-configured server racks are a common example. In a typical scenario, the end recipient of a computer system is not in the shipping business and will not have the know-how or equipment to easily unload the computer system from the pallet. Given the great weight of computer systems, the recipient may risk injury or damage to the cargo by unloading the cargo improperly.  
         [0007]     One solution to this problem is to ship unloading ramps with the cargo and pallet. Such ramps may be mountable to the pallet to ease the movement of the cargo from the pallet to the ground. However, unloading ramps present some additional difficulties. For example, if the ramp is not properly secured to the pallet, it may shift while the cargo is unloading, with potentially disastrous results. If the top of the ramp is not aligned with the top of the pallet, the cargo may experience a ruinous jolt when it falls from the pallet onto the ramp. Alternatively, if the ramp is higher than the top of the pallet, the cargo may tend to catch on the ramp and tip as it is pushed off the pallet or push the ramp away from the pallet altogether.  
         [0008]     Prior attempts to bundle ramps with a pallet and cargo have a number of deficiencies. Some fail to provide any mechanisms for securing the ramp to the pallet. Those attempts that secure the ramps to the pallet require user intervention to secure the ramps to the pallet. That is, the user must both position the ramp and take steps to secure the ramp to the pallet. Requiring users to take additional steps to secure the ramp to the pallet is problematic for two reasons.  
         [0009]     First, due to the inexperience of the typical user, a user who is unloading cargo may not realize that additional steps are needed to secure a ramp. Therefore, a user may not be prompted to, for example, find a fastener among the packaging of a computer system and may neglect to use the fastener to secure the ramp.  
         [0010]     Secondly, in order for a user to secure a ramp to a pallet using a fastener, such as a bolt, the ramp and pallet must be precisely sized. For example, to secure the ramp to the pallet with a bolt, an aperture on the ramp must typically be aligned with an aperture on the pallet in order to insert the bolt there through. This requirement for alignment imposes excessive requirements for dimensional precision. Pallets and ramps are typically made very inexpensively out of rough-cut boards subject to very loose tolerance in both their size and position when assembled. Requiring precise measurements when placing holes to receive bolts increases the cost of an otherwise simple article.  
         [0011]     In addition, pallets are subject to rough handling and moisture during shipping, both of which can affect the shape and size of the pallet. The weight of cargo may deform the pallet or crush portions of the pallet. Moisture causes wood to swell and distort. This deformation of the pallet during shipment makes aligning the ramp and pallet for securement with traditional fasteners even more difficult. Even where a fastener is usable to fasten the ramp to the pallet, distortion of the pallet may cause the upper surface of the ramp to be misaligned with respect to the upper surface of the pallet, leading to difficulties in unloading.  
         [0012]     From the foregoing discussion, it should be apparent that a need exists for an apparatus, system, and method that can securely attach a ramp to a pallet without the need for a separate fastener. Such a device should integrate the steps of positioning the ramp and securing the ramp to the pallet to accommodate inexperienced users. Beneficially, such an apparatus would align the upper surface of the ramp with the upper surface of the pallet without the need for precise construction of the pallet and without regard to distortion of the pallet.  
       SUMMARY OF THE INVENTION  
       [0013]     The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available pallet ramps. Accordingly, the present invention has been developed to provide an apparatus, system, and method for integrating the steps of securing an unloading ramp to a pallet and aligning the ramp to the pallet, thereby overcoming many or all of the above-discussed shortcomings in the art. It will be noted that the invention provides an apparatus, system, and method for aligning and securing a first surface or structure with respect to a second surface or structure.  
         [0014]     A first surface may comprise a relatively flat surface such as a platform or floor. The second surface may comprise an inclined surface such as a ramp or plank. Of course the first and second surfaces may have the same slope. Typically, the first surface comprises an upper surface of a pallet and the second surface comprises an under surface of a ramp. Such an apparatus, system and method may be used with other types of ramps or with other applications requiring such functionality.  
         [0015]     The apparatus for securing a pallet to a ramp is provided with a pallet for facilitating the transport of cargo and an unloading ramp for aiding in unloading the cargo from the pallet. The apparatus, in one embodiment, is configured to substantially simultaneously secure the ramp to the pallet during unloading and align the ramp with respect to the pallet.  
         [0016]     In one embodiment, a fastener secures to the ramp and is positionable within a locking receptacle secured to the pallet. An engagement portion secures to the ramp and is positioned to engage a driver secured to the pallet. As the engagement portion is brought into engagement with the driver, the driver urges the engagement portion, and thus the ramp, to an operable position wherein the fastener is engaged with the locking receptacle. When engaged with the locking receptacle, the fastener is typically restrained against movement in the vertical direction.  
         [0017]     Some embodiments may include a registration member secured to the ramp and a registration receptacle secured to the pallet. The registration member may be inserted into the registration receptacle to position the ramp during engagement of the driver with the engagement portion. Registering the ramp may ensure that the engagement portion is positioned proximate the driver and that the fastener is positioned proximate the locking receptacle.  
         [0018]     In one embodiment, the driver, locking receptacle, and registration receptacle are all formed as part of a pallet mounting bracket secured to the upper surface of the pallet. In a like manner, the engagement portion, fastener, and registration member may all be formed as part of a ramp mounting bracket secured to a lower surface of the ramp.  
         [0019]     A driver and engagement portion may be embodied as angled portions of the pallet mounting bracket and ramp mounting bracket, respectively. As the angled portions are pushed downwardly against each other, a resulting longitudinal force urges the engagement portion longitudinally, thereby forcing the fastener into the locking receptacle.  
         [0020]     A fastener may be embodied as a portion of a tab extending from the ramp mounting bracket. The locking receptacle may be a receptacle formed in the pallet mounting bracket and positioned to receive insertion of the tab and restrain the tab vertically.  
         [0021]     A registration member may be embodied as a portion of the tab that inserts into a portion of the aperture sized to receive it. For example, a tab may include a wide portion and a narrow portion forming downwardly-extending, upside-down “T.” The registration member may be considered to be the horizontal line of the T and the fastener may be considered to be the under side of the horizontal line.  
         [0022]     The aperture may likewise include a wide portion and a narrow portion, forming a horizontal T, with the wide portion closest to the edge of the pallet. The registration receptacle may be considered to be the wide portion of the aperture and the locking receptacle may be considered to be the narrow portion of the aperture  
         [0023]     To register the ramp with respect to the pallet, the tab is inserted into the wide portion of the aperture. The ramp may then be lowered to engage the engagement portion with the driver. As the driver urges the engagement member longitudinally, the tab is urged into the narrow portion of the aperture. The wide portion of the tab is then restrained against vertical movement, inasmuch as it cannot pass through the narrow portion of the aperture  
         [0024]     A method for using the foregoing apparatus may include registering the ramp with respect to the pallet, transitioning the ramp, engaging the engagement portion with the driver, and engaging the fastener with the locking receptacle. Registering the ramp may include inserting the registration member into the registration receptacle. Transitioning the ramp may include moving the ramp downwardly, moving the engagement portion toward the driver. Engaging an engagement portion with the driver may include lowering the ramp to cause the engagement portion to press against the driver, creating a resulting longitudinal force on the ramp. Engaging the fastener with the locking receptacle may include inserting the fastener into the locking receptacle such that the fastener is restrained against vertical movement.  
         [0025]     Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.  
         [0026]     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.  
         [0027]     These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0028]     In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:  
         [0029]      FIG. 1  is perspective view of a pallet, ramp, and pallet mounting bracket, in accordance with the present invention;  
         [0030]      FIG. 2  is an upper perspective view of a pallet mounting bracket having a registration receptacle, locking portion, and driving member, in accordance with the present invention;  
         [0031]      FIG. 3  is a perspective view of a ramp mounting bracket having a registration member, fastener, and engagement portion, in accordance with the present invention;  
         [0032]      FIG. 4  is a process flow diagram of a method for securing a ramp to a pallet, in accordance to the present invention;  
         [0033]      FIG. 5A  is a top view of a pallet mounting bracket and ramp mounting bracket with the registration member inserted into the registration receptacle, in accordance with the present invention;  
         [0034]      FIG. 5B  is a side view of a registration member and registration receptacle, in accordance with the present invention;  
         [0035]      FIG. 5C  is a side view of a pallet mounting bracket and ramp mounting bracket with the engagement portion engaged with the driving member of the pallet mounting bracket, in accordance with the present invention;  
         [0036]      FIG. 5D  is a top view of a pallet mounting bracket and ramp mounting bracket with the fastener engaged with the locking portion, in accordance with the present invention; and  
         [0037]      FIG. 5E  is a side view of a fastener engaged with the locking portion, in accordance with the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.  
         [0039]     Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention can be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.  
         [0040]     Referring to  FIG. 1 , an apparatus  100  for loading or unloading cargo may define translational directions  102   a - 102   c  and rotational directions  104   a - 104   c  defined with respect to a pallet  110 . Transverse direction  102   a  may be substantially normal to the upper surface  112   a  of the pallet  110 . Longitudinal direction  102   b  may be defined as parallel to the upper surface  112   a  of the pallet  110  and correspond to the direction of travel of cargo as the cargo is unloaded. A lateral direction  102   c  may be defined as being perpendicular to both the transverse direction  102   a  and longitudinal direction  102   b . Rotational directions  104   a - 104   c  are defined as rotation about axes parallel to the translational directions  102   a - 102   c , respectively.  
         [0041]     A pallet  110  may include an upper surface  112   a  for supporting cargo and a lower surface  112   b  spaced apart in transverse direction  102   a  from the upper surface  112   a . The upper surface  112   a  may define a loading edge  114  defined as the edge of the pallet  110  proximate to which a ramp will secure. In some embodiments, the pallet  110  may include one or more channels  116  extending in longitudinal direction  102   b . A channel  116  may secure portions of the cargo against movement in lateral direction  102   c  during shipping and unloading. In certain embodiments, a shelf  120 , cut out  120 , or other formation  120 , may be formed at one end of the channel  116  to mate with a corresponding structure on a ramp.  
         [0042]     A ramp  122 , or ramps  122  may be attached to the pallet  110  prior to unloading cargo. In applications where a ramp is used to load cargo onto a pallet  110 , the ramp  122  may secure to the pallet  110  prior to loading of the cargo. A ramp  122  may have a channel  124  formed thereon and positioned to mate with the channel  116  of the pallet  110  to provide a continuous guide from the pallet to a supporting surface, such as the floor of a building. In typical embodiments, an upper edge  126  of the ramp  122  will be aligned in transverse direction  102   a  with the channel  124  to prevent unloaded cargo from falling from the channel  116  to the channel  124 . The channel  124  will typically extend from the upper edge  126  to a lower edge  128  resting on or near a support surface when the ramp is fully secured to the pallet  110 . It will be noted that for embodiments of the apparatus  100  that do not include channels  116  or  124 , an upper surface of the ramp  122  may simply be aligned with the upper surface  112   a  of the pallet  100 .  
         [0043]     A ramp  122  may include a portion  130  of the ramp  122 , cutout  130 , or like formation matable with the shelf  120  formed on the pallet  110 . The portion  130  may support the upper edge  126  and facilitate alignment of the channels  116 ,  124 .  
         [0044]     A pallet mounting bracket  140  may be secured to the upper surface  112   a  of the pallet  110  near the unloading edge  114 . The bracket  140  may engage a corresponding bracket (discussed in more detail below) secured to the ramp  122 . A pallet mounting bracket  140  may perform the functions of securing and aligning the ramp  122  to the pallet  110 . A benefit of the bracket  140  is that it is a separate member that is simply fastened to the pallet  110  by standard fasteners. The pallet  110  may still be made of wood cut to loose tolerances, and only the bracket  140  and its position require greater precision. The bracket  140  may be made of stamped sheet steel, or like material, having similar strength and manufacturability. Alternatively, the bracket  140  may be integrally formed with the upper surface  112   a  of the pallet  110 .  
         [0045]     Referring to  FIG. 2 , a pallet mounting bracket  140  may include a registration receptacle  202 , a driving member  204 , and a locking receptacle  206  for engaging structures on the ramp  122  to secure and align the ramp  122  to the pallet  110 . In the illustrated embodiment, the registration receptacle  202  and locking receptacle  206  are embodied as a portion of an aperture  208  formed in an upper portion  210  of the bracket  140 . A locking receptacle  206  may be embodied as a narrow portion  212  of the aperture  208  having a width  214 . The registration receptacle  202  may be embodied as a wide portion  216  of the aperture  208  having a width  218  greater than the width  214  of the narrow portion  212 .  
         [0046]     The top portion  210  may be positioned a height  222  above the pallet  110  in order to permit insertion of a fastener and registration member through the aperture  208 . Accordingly, in some embodiments, the top portion  210  may rest on two upwardly extending portions  224   a  and  224   b.    
         [0047]     A driving member  204  may be embodied as a portion of the bracket  140  positioned to urge the ramp  122  toward alignment, securement, or both, with the pallet  110  upon some movement of the ramp  122 . For example, such movement may include pivoting or lowering the ramp  122  toward the bracket  140 . In the illustrated embodiment, the driving member  204  is an angled portion  226  of the bracket  140 . The angled portion  226  may begin angling upwardly in transverse direction  102   a  a distance  228  from the upwardly extending portion  224   a . A securement portion  229  may extend between the upwardly extending portion  224   a  and the angled portion  226 . The securement portion  229  may receive bolts, or like fasteners, for securing the bracket  140  to the pallet  110 . The angled portion  226  may form an angle  230  of about 135 degrees relative to the securement portion  229 .  
         [0048]     A bracket  140  may have a width  232  corresponding to the width of the ramp  122  selected for use therewith. Accordingly, a bracket  140  may be wide for a wide ramp, and narrow for a narrower ramp. A bracket  140  may include a plurality of registration receptacles  202  and locking receptacles  204  likewise corresponding to the width of the ramp, with wider ramps having more receptacles  202 ,  204 . Preferably, the receptacles  202  are distributed along the bracket  140  in lateral direction  102   c  and aligned with each other.  
         [0049]     It will be noted that in some embodiments the portions of the pallet mounting bracket  140  performing distinct functions may be formed as distinct members, rather than as monolithic portions of the pallet mounting bracket  140 . For example, the angled portion  226  and the top portion  210  having the aperture  208  formed therein may be separate members independently secured to the pallet  110 .  
         [0050]     Referring to  FIG. 3 , ramp mounting bracket  300  may secure to the ramp  122  and engage the pallet mounting bracket  140  to secure and align the ramp  122  to the pallet  110 . A ramp mounting bracket  300  may include a registration member  302  for both inserting into the registration receptacle  202  and a fastener  304  engaging the locking receptacle  206 . A ramp mounting bracket  300  may likewise include an engagement portion  306  for engaging the driving member  204  of the pallet mounting bracket  140 . A fastener  304  may be automatically engaged with the locking receptacle  206  or may be manually inserted by a user. For example, a fastener  304  may be a bolt that is manually inserted through apertures formed in the pallet mounting bracket  140  and ramp mounting bracket  300 .  
         [0051]     In the illustrated embodiment, the registration member  302  and fastener  304  are embodied as portions of a tab  308  secured to the ramp mounting bracket  300 , or formed monolithically therewith. The tab  308  typically extends downwardly in transverse direction  102   a . The registration member  302  may be embodied as a wide portion  310  having a width  312  slightly smaller than the width  218  (see  FIG. 2 ) of the wide portion  216  of the aperture  208  formed in the pallet mounting bracket  140 . A fastener  304  may be embodied as a cutout  314 , or shoulder  314  formed in the tab  308 , creating a narrow portion  316  on the tab  308  having a width  318  slightly smaller than the width  214  (see  FIG. 2 ) of the narrow portion  212  of the aperture  208  formed in the pallet mounting bracket  140 .  
         [0052]     The engagement portion  306  may be embodied as an angled portion  320  connected or secured to the ramp mounting bracket  300  or formed monolithically therewith. The angled portion  320  may form an angle  324  of 45 degrees. The angled portion  320  and tab  308  may be secured to a securement portion  322 . The securement portion  322  may secure directly to the ramp  122  by means of bolts, screws, or like fastener.  
         [0053]     It will be noted that in some embodiments the portions of the ramp mounting bracket  300  performing distinct functions may be formed as distinct members, rather than as monolithic portions of the ramp mounting bracket  300 . For example, the angled portion  320  and tab  308  may be separate members independently secured to the ramp  122 .  
         [0054]     Referring to  FIG. 4 , a method  400  for securing a ramp  122  to a pallet  110  may include registering  410  the ramp  122 , transitioning  420  the ramp  122 , engaging  430  a driving member  204  with an engagement portion  306 , and engaging  440  a fastener  304  with a locking receptacle  206 . It will be noted that a method for removing a ramp  122  is simply the reverse of the actions described as part of the method  400 .  
         [0055]     Referring to  FIGS. 5A and 5B , while still referring to  FIG. 4 , registering  410  the ramp  122  may include aligning the ramp  122  in at least one dimension with respect to the pallet  110  in order to position the engagement portion  306  sufficiently close to the driving member  204  to engage the driving member  204  in the transitioning step  420 . Registering  410  may also position the fastener  304  in sufficient proximity to the locking receptacle  206  such that the driving member  204  urges the locking receptacle  206  into engagement with the fastener  304  during engagement  440  of the driving member  204  with the engagement portion  306 .  
         [0056]     In the illustrated embodiment, registering  410  the ramp  122  includes positioning the ramp in the lateral direction  102   c  and roughly positioning the ramp  122  in the longitudinal direction  102   b . A user may be aided in registering  410  the ramp  122  by engaging the registration member  302  with the registration receptacle  202 . In the illustrated embodiment of  FIG. 5A , registering  410  therefore includes inserting the wide portion  310  of the tab  308  into the wide portion  216  of the aperture  208 .  
         [0057]     Referring to  FIG. 5C , while still referring to  FIG. 4 , transitioning  420  the ramp  122  may include translating and/or rotating the ramp  122  substantially along a line of action or substantially about axis of rotation fixed in the registering step  410 . In the illustrated embodiment, transitioning  420  the ramp  122  includes rotating the ramp  122  downwardly in rotational direction  104   c  about the point of contact between the ramp mounting bracket  300  and the pallet mounting bracket  140 . In the illustrated embodiment, transitioning  420  the ramp  122  may also include translating the ramp  122  toward the pallet  110  in transverse direction  102   a.    
         [0058]     Engaging  430  the driving member  204  with the engagement portion  306  includes urging the engagement portion  204  against the driving member  306  to translate a force exerted on the ramp  122  in one direction into a force acting in another direction. For example, a rotational or downward force exerted on the ramp  122  in the transitioning step  420  may be translated into a longitudinal force in the engaging step  430 .  
         [0059]     In the illustrated embodiment of  FIG. 5C , engaging  430  the driving member  204  with the engagement portion  306  includes urging the angled portion  320  of the ramp mounting bracket  300  against the angled portion  226  of the pallet mounting bracket  140 , thereby causing a resulting force on the ramp mounting bracket  300  urging the ramp  122  in longitudinal direction  102   b.    
         [0060]     Referring to  FIGS. 5D and 5E , while still referring to  FIG. 4 , engaging the fastener  304  with the locking receptacle  206  may include engaging the narrow portion  316  of the tab  308  with the narrow portion  212  of the aperture  208 . The shoulder  314 , of the tab  308  will therefore prevent removal of the tab  308  from the aperture  208 , unless the tab  308  is translated back in the longitudinal direction  102   b.    
         [0061]     Engaging fastener  304  with the locking portion  206  may be caused by the longitudinal motion forced by engagement of the engagement portion  306  with the driving member  204 . It will be noted that the engagement of the driving member  204  with the engagement portion  306  prevents removal of the ramp  122  from the pallet  110  during unloading of cargo, inasmuch as the weight of the cargo will continuously press the engagement portion  306  against the driving member  204 , in turn forcing the fastener  305  to remain inserted in the locking receptacle  206 .  
         [0062]     The longitudinal force caused by urging the engagement portion  306  against the driving member  204  also urges the edge  126  of the ramp  122  into transverse alignment with the channel  116  formed in the pallet  110 . It will be noted that inasmuch as the pallet mounting bracket  140  is mounted on the upper surface  112   a  of the pallet  110  in some embodiments, a ramp  122  engaging the bracket  140  will be alignable in most cases regardless of any crushing or distortion of the pallet  110  beneath the upper surface  112   a    
         [0063]     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.