Patent Publication Number: US-8522694-B2

Title: Structural supporting pallet construction with improved perimeter impact absorbing capabilities

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of Provisional Application No. 61/522,847, filed Aug. 12, 2011. This Application is also a Continuation-in-part of application Ser. No. 12/467,601 filed on May 18, 2009, which claims the benefit of U.S. Provisional Application 61/074,306 filed on Jun. 20, 2008 and is a Continuation-in-part of application Ser. No. 12/414,017 filed on Mar. 30, 2009. This Application is also a Continuation-in-part of application Ser. No. 13/081,953 filed on Apr. 7, 2011, which claims the benefit of U.S. Provisional Application 61/328,682 filed on Apr. 28, 2010 and is a Continuation-in-part of application Ser. No. 12/608,512 filed on Oct. 29, 2009, which is a Continuation-in-part of both application Ser. No. 12/467,601 filed on May 18, 2009 and application Ser. No. 12/414,017 filed on Mar. 30, 2009. 
    
    
     FIELD OF THE INVENTION 
     A structural supporting and stackable pallet construction incorporating a reinforcing and internal grid like skeletal structure exhibiting enhanced load characteristics. A plurality of perimeter located impact absorbing members are arranged about the sides of the pallet and operate to minimize the damage inflicted by forklift inserting forks within configured receipt apertures in the sides of the pallet in order to maintain and extend the useful life of the assembly. 
     DESCRIPTION OF THE RELEVANT ART 
     The relevant art is well documented with various type of pallet designs. In additional to conventional wood pallets, additional materials including plastics and the like have been utilized in the construction of load bearing pallets, with varying degrees of effectiveness. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention discloses a pallet exhibiting a rectangular shaped and three dimensional body including an outer frame and a pair of inner and crosswise extending grid supports. Each of a plurality of sides associated with the outer frame further includes at least one forklift receiving apertures. A plurality of individual support surfaces are established between the outer frame and the inner extending crosswise supports, a corresponding plurality of planar shaped portions being installed upon the support surfaces and establishing a generally flush appearance with surrounding top edges of the body. 
     Additional features include the outer frame and inner crosswise extending supports being constructed of any of a wood, polymer, polymer composite or metal. Reinforcing brackets are secured to underside edges of the outer frame in order to establish the forklift receiving apertures. Underside projecting stand-offs associated with at least the crosswise supports are provided for creating structural support along an entire underside area associated with the body. 
     Other features include the provision of inner ledge supports extending around an inner perimeter defined by each of the individual support surfaces for supporting an installed planar shaped portion. An aperture pattern may also be defined in each of the outer frame and inner crosswise extending supports. 
    
    
     
       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 an upper perspective of a pallet construction, with top layer removed, and illustrating the combination of features including grid reinforcing inner construction, additional supporting material reinforcement members, and perimeter edge extending impact absorbing members; 
         FIG. 2  is a further rotated underside view of the pallet construction and further depicting the optional underside standoff frame attachment for facilitating conveyor supporting of the pallets in combination with providing additional forklift retaining aspects; 
         FIG. 3  is an upper perspective illustration of a modified pallet construction, again with top layer removed, and illustrating cross shaped reinforcement inserts in combination with modified configuration of impact absorbing members; 
         FIG. 4  is a rotated underside of either of  FIGS. 1 and 3  and better showing the arrangement of hand holds in combination with the underside pallet profile; 
         FIG. 5  is an enlarged upper side perspective and better depicting a further modification of the segmented energy absorbing members such as depicted in  FIG. 3 , these including individual section defining reinforcing members with engineered flex points; 
         FIG. 6  is an upper facing perspective of a pallet construction according to a yet further variant and illustrating a substantially impact absorbing planar extending and load supporting surface with integrally formed outer and grid extending frame construction; 
         FIG. 7  is a rotated underside of the pallet construction of  FIG. 6  and better depicting the features of the galvanized steel extending perimeter along with the provision of such as impact absorbing material strips filling inner channels associated with the galvanized supporting grid; 
         FIG. 8  is an upper facing perspective of a further variation of pallet construction including an outer frame and inner grid constructed of a wood or composite material and which defines a plurality of sections which are each filled with a foam or suitable composite material; and 
         FIG. 9  is a yet further variation of a pallet construction of a nature depicted in  FIG. 8  and further illustrating a metal outer frame and inner defining grid, the inner and crosswise extending grid members each exhibiting apertures which provide both weight reduction and/or permit inter-filling of any type of material such as a structural foam, wood, composite thereof or other fill-able material. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the following illustrations, a series of variants are shown of a structural supporting and stackable pallet construction incorporating a reinforcing and internal grid like skeletal structure exhibiting enhanced load characteristics. This, combined with perimeter located impact absorbing members arranged about the sides of the pallet, minimizes the damage inflicted by forklift inserting forks within configured receipt apertures in the sides of the pallet in order to maintain and extend the useful life of the assembly. 
     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 be further described in detail, the material construction of the pallets includes any combination of heavy duty paperboard, plastic, metal or composite admixture. As will be additionally described, the completed pallet article encompasses any desired arrangement or pattern of interiorly extending open apertured locations, recesses or other configurations, these further reducing the overall weight of the pallet without compromising its strength. 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 now to  FIG. 1 , an upper perspective is generally shown at  10  of a pallet construction, with top layer removed, and which exhibits a generally flattened rectangular shape with an established thickness. The pallet is constructed of any suitable material, including any paperboard like corrugated material, plastic or composite thereof and exhibits a generally rectangular profile with four sides  12 ,  14 ,  16  and  18 , each of which are further configured to integrate lift fork receiving apertures, see upwardly recessed base surfaces at  20  and  22  for side  12  as well as further at  24  and  26  for adjoining side  14 , with identical pairs of spaced apertures being associated with each of succeeding sides  16  and  18 . 
     The fork receiving apertures as shown exhibit three sided underside recessed and inner perimeter edges communicating with bottom surfaces of the associated sides  12 ,  14 ,  16  and  18 . As further shown in the rotated underside view of  FIG. 2 , the pallet construction further includes an optional underside standoff frame attachment for facilitating conveyor supporting of the pallets in combination with providing additional forklift retaining aspects. 
     The frame attachment is depicted by four individual and end-to-end connected and flattened “L” shaped segments  28 ,  30 ,  32  and  34 , it being understood that the frame attachment can be provided with any number of pieces, down to a one piece four sided frame, and which are permanently or releasably attached to underside surfaces of the pallet sides (see as shown by depicted underside surfaces  36 ,  38 ,  40 ,  42  and  44  for contiguous sides  12  and  14 ) with the use of any of clips, mechanical/chemical adhesives or the like. Without limitation, the frame attachments can be constructed of any suitable material not limited to a metal, plastic, wood or any manner or type of composite material. Secondary advantages associated with the bottom attachment frame include assisting in retaining the inserted forks of the lift. 
     Referring again to  FIG. 1 , an internal supporting grid arrangement is depicted and defines a reinforcing structural interior of the pallet. A plurality of interlocking ribs are arranged in a desired grid, pattern or lattice arrangement. These are depicted in  FIG. 1  by extending and spaced apart pluralities of ribs  46 ,  48 ,  50 , et seq. (extending between sides  12  and  16 ), crosswise extending and spaced apart ribs  52 ,  54 ,  56 , et seq. (between alternating sides  14  and  18 ) and diagonal ribs  58  and  60 . 
     Reinforced and deepened areas of the grid construction include a central most ribs  62  (see also  FIGS. 2 and 4 ), as well as perimeter spaced portions  64 ,  66 ,  68 ,  70 ,  72 ,  74 ,  76  and  78  extending along sides  12 ,  14 ,  16  and  18 . The arrangement and spacing of the deepened structural grid portions  64 - 78  define the underside receiving forklift apertures (again depicted at  20 ,  22 ,  24  and  26  for selected sides  12  and  14  and as further defined by pairs of spaced apart and vertical side surfaces  65 ,  67 ,  69  and  71  in  FIG. 4  which establish the underside defining configuration for facilitating forklift insertion). Further hand hold apertures are shown at  80 ,  82 ,  84  and  86  in  FIG. 4  and which are designed into the body of the pallet both to reduce overall weight as well as to provide for convenient grasping and transport of the pallet. 
     As with the top, bottom and side surface layers of the pallet the grid defining ribs are again constructed of any suitable corrugated paperboard, plastic or composite material. A suitable plasticized coating or spray, such as which enhances the structural aspects of the assembly as well as restricts/impedes/impairs the absorption and contamination of water, can also be either pre or post applied after assembly or molding of the grid members. 
     Additional structural reinforcing support can be provided in the form of elongated members  88  and  90  (depicted as substantially flattened and elongated slats), such as extending along interior intermediate locations of the pallet (in the illustrated instance in inwardly parallel spaced fashion relative to parallel sides  12  and  16 ). The elongated members  88  and  90  can exhibit any desired dimensions (length, width and thickness) as well as be constructed of any material including wood, plastic metal or composite material and which is dimensioned to fit within integrally configured channels or pockets defined within the interior grid structure of the pallet and for contributing additional structural support to the assembly. 
     Referring still to  FIG. 1 , a plurality of perimeter edge extending and individual impact absorbing members are depicted at  92 - 122  in contiguous and perimeter extending fashion around and in proximity to the sides  12 ,  14 ,  16  and  18 . The impact absorbing members as shown each are constructed in a generally three dimensional rectangular block or brick shape (selected absorbing members  102 ,  106 ,  118  and  122  further exhibiting notched locations to seat extending ends of the inner elongated support members  88  and  90  as shown). The material construction of the impact absorbing members further can include any of a variety of materials, such as but not limited to a foam, corrugated paper or plastic. 
     As further shown in  FIG. 1 , additional perimeter located grid support locations are defined by additional ribs (see as representatively shown at  124 ,  126  and  128  in  FIG. 1  in association with selected impact absorbing member  94  and located contiguous to a next intermediate row of inner structural rib supports represented by selected ribs  46 ). The inner interconnecting and crosswise extending relationship established by the ribs  124 - 128  is constructed so as to define individual cushioning/controlled collapsible pockets which, in the event of a misalignment impact of inserting lift forks (not shown) will facilitate localized impact absorption of the misdirected forks into one or more of the impact absorbing members, and further without materially impacting the overall structural integrity of the pallet, such as by unnecessarily deforming or impacting the next inner row  46  of ribs. The dimensions and construction of the impact absorbing members and associated periphery located and pocket defining ribs are further such that the members can be modified to assume any other desired shape or configuration, such as for adapting the pallet to any desired operating configuration, weight or support rating, and without otherwise impacting the operational capabilities of the design. 
     Additional features include a plurality of upper edge extending and raised locating/alignment portions  130 - 152  extending at spaced apart locations about the periphery of the pallet (these again associated with an upper surface layer of the pallet which is removed in  FIG. 1  to permit illustration of the interior components). The locating and alignment portions alternate with notched and inwardly stepped recesses associated with mating extending edge locations associated with the undersides of each pallet and, as best shown in the underside of  FIG. 4 , corresponds to mating lower edge locations  154 - 176  defined in the lower and edge spaced projecting portions  64 - 78 , this facilitating secure stack-ability for storage or transport of the pallets when not in use. 
     Referring now to  FIG. 3 , an upper perspective illustration is show of a modified pallet construction, generally shown at  178 , again with top layer removed, and which illustrates cross shaped reinforcement inserts (see first diagonal extending insert  180  and cross wise extending and segmented diagonal inserts  182  and  184 ). The elongated inserts  180  and  182 / 184  each approximate the dimensions of a 2×2 stud or the like. In combination, a modified configuration of impact absorbing members is further depicted by a reduced number of spaced apart members  186 - 200 , these located at end/corner and intermediate locations of the pallet sides and which are offset with the associated and underside defining fork recesses. 
     As shown, selected corner positioned impact absorbing members  186 ,  190 ,  194  and  198  are reconfigured to seat diagonal extending ends of the members  180 ,  182  and  184 . Each impact absorbing member further includes a perimeter defining box of trim portions (see as representatively shown at  202 ,  204 ,  206  and  208  for selected impact absorbing member  188 ), these being constructed of any type of wood, plywood, plastic, metal or composite and which, in combination with a foam, corrugated paper or plastic composition associated with any of the impact absorbing members  186 - 200 , provides a like desired degree of localized (lift fork) impact absorbing capabilities without compromising the overall integrity of the pallet. 
     The pallet  178  includes a similar arrangement of grid defining ribs as previously described in reference to  FIG. 1  such that a repetitive description is unnecessary. The ribs are again configured integrally within the pallet interior to facilitate placement and location of the diagonal reinforcing supports  180 ,  182  and  184  and spaced apart outer perimeter located impact absorbing members  186 - 200 , with the exception that they are reconfigured to the extent to accommodate the diagonal extending inner structural supports  180 ,  182  and  184  in substitution for the elongated inner extending supports  88  and  90  depicted in  FIG. 1 . 
       FIG. 5  is an enlarged upper side perspective and better depicting a further modification of the segmented energy absorbing members, similar to as previously depicted in  FIG. 3 , and which is illustrated by selected absorbing portions  210 ,  212  and  214 , each of which includes individual section defining reinforcing members with engineered flex points and as further depicted by respective offset trim portions  216 ,  218 ,  220  and  222  for selected absorbing portion  210 . The inwardly extending gap or offset established between shorter trim portion legs  218  and  222 , relative to outer  216  and inner parallel  220  trim pocket defining locations facilitates a degree of localized and inwardly flexing collapse which provides another variation of enhanced structural give in the event of a misalignment impact of a lift fork, again without impacting the overall integrity of the pallet construction. 
       FIG. 6  is an upper facing perspective, generally at  224 , of a pallet construction according to a yet further variant and illustrating a substantially impact absorbing planar extending and load supporting surface with integrally formed outer and grid extending frame construction. This is further evidenced by individual body sections  226 ,  228 ,  230  and  230 , each of which are constructed of foam, corrugated or plastic materials and which are bounded by any of a metal, plastic, wood or composite outer frame, further depicted by outer frame/side defining members  231 ,  232 , et seq. and corresponding and depth extending portions  234 ,  236 ,  238 , et seq. which confirm with the individual planar foam or other sections  226 ,  228 ,  230  and  232  in order to collectively define the surface extending profile of the pallet  224 . 
     A crosswise extending grid  240  and  242  is incorporated into the pallet construction  224  and integrates into the perimeter frame construction (such as depicted including a galvanized steel or like construction) to provide additional structural support to the design. An outer plasticized coating or spray  244  can be applied to the exterior of the individual and three dimensional formed sections  226 - 232  and associated galvanized frame surfaces  230 - 242 . Suitable hand hold surfaces  246 ,  248 ,  250  and  252  can also be integrated into the design of the durable foam constructions  226 - 232  as shown. 
     Referring to  FIG. 7 , a rotated underside of the pallet construction of  FIG. 6  is depicted and better depicting the features of the galvanized steel extending perimeter along with the provision of such as impact absorbing material strips (again depicted by galvanized edge locations  234 ,  236 ,  238  et seq.) for providing a degree of combined surface protection and impact absorbing support to the pallet construction. The pallet configuration  224  of  FIGS. 6 and 7  can further exhibit a substantially hollow interior construction within at least each of the enlarged and depth defining portions and which, in combination with the galvanized steel (or other) frame and foam section supporting surfaces, define a relatively lightweight and load capable bearing construction. The structural substrate can exhibit, without limitation, any desired length, width, height/thickness dimension. It is also envisioned and understood that the construction and arrangement of the interior structural supporting portions are not limited to those illustrated and that further structural defining interior patterns or structure beyond those shown are also envisioned. 
     Referring now to  FIG. 8 , an upper facing perspective is generally depicted at  254  of a further variation of pallet construction and which includes a four sided outer structural wood, polymer, wood/polymer or other composite, constructed frame, see sides  256 ,  258 ,  260  and  262 , each of which including upper edge extending and raised locating/aligning portions (for example at  264 ) and corresponding underside notched and inwardly stepped recesses (representatively at  266 ) similar to those previously described and for facilitating multiple stackability of the pallets when not in use. Each of the sides further exhibits lengthwise extending and rectangular shaped inner perimeter defining forklift receiving apertures, further defined in respective pairs  268 ,  270 ,  272  and  274  for each of corresponding sides  256 ,  258 ,  260  and  262 . As best exemplified by selected lift receiving apertures  272 , an inner extending and three sided bracket reinforcement, depicted by sides  237  and  275  with upwardly angled lip edges for engaging to the underside surface of the indicated extending side edge  272 , with bottom interconnected shelf  276  a downwardly spaced distance therefrom in order to define a rectangular pocket of a dimension suitable for receiving an inserting lift fork and such as is provided for creating the side accessible lift aperture while at the same time cooperatively establishing additional structural integrity to the outer walls/sides of the frame construction. 
     An inner grid of crosswise extending supports is depicted at  278  and  280  and which are constructed of a wood or composite material, similar to the outer frame. Upon assembly, as shown, the inner grid defines a plurality of inner sections  282 ,  284 ,  286  and  288 , the first of which is further depicted filled with a foam or suitable composite material in order to create a load supporting surface. 
     As with prior embodiments, the foam or composite planar subsection of material can be preformed to include an inner configured handhold, see further at  290 , in order to facilitate ease of transport of the pallet. The grid supports  278  and  280  further depict underside extending stand-off locations, see at  292 ,  294  and  296  at both center and outer perimeter locations of at least the crosswise extending supports  278  and  280  in order to establish dimensional and load supporting stability across an entire underside surface area of the pallet assembly and to permit the configuration and dimensioning of the side disposed lift receiving apertures  268 ,  270 ,  272  and  274  in the deepened side members  256 - 262 . 
     The individual sections  282 ,  284 ,  286  and  288  are further defined, by volume, by such as underside ledges (see for example at  298 ,  300 ,  302 , et seq.) and which extending from each of four inwardly facing sides associated with the frame and crosswise support for individually supporting the tile or sheet constructed foam or composite sections  282  during installation. As shown, the inserted and structurally supported sheets (e.g. again at  282 ) exhibit a thickness less than the overall height of the pallet  254  and such that they seat within section defined apertures in supported fashion upon the inwardly extending side ledges  298 ,  300 ,  302  et seq., extending inwardly along each of four interconnected and inner perimeter defining sides and in a manner in which the top edges of the foam or composite sections extend flush with the top edge surfaces of the outer frame and inner crosswise extending supports. 
     Referring finally to  FIG. 9 , a yet further variation of a pallet construction is generally shown at  304  of a nature depicted in  FIG. 8  and further illustrating a four sided metal outer frame (sides  306 ,  308 ,  310  and  312 ) which include a similar arrangement of lengthwise extending and rectangular shaped inner perimeter defining forklift receiving apertures, and which are further defined in respective pairs  314  and  316  (with a portion of a further reverse side aperture  318  substantially hidden on the backside but evident through section hand holds) and further at  320  respectively for each of corresponding sides  306 ,  308 ,  310  and  312 . As best exemplified by selected lift receiving apertures  320 , a plurality of inner extending and three sided bracket reinforcements (such as representatively shown at  322 ) are constructed similar to as described in  FIG. 8  and are again provided for creating the side accessible lift aperture as well as cooperatively establishing additional structural integrity to the outer walls/sides of the frame construction. 
     An inner grid of crosswise extending supports is depicted by members  324  and  326  which is constructed of a like metal material, similar to the outer frame. Upon assembly, as shown, the inner grid defines a plurality of inner sections  328 ,  330 ,  332  and  334 , the first two of which are further depicted by foam or composite square shaped materials, or tiles, emplaced and in order to create a load supporting surface. 
     As with prior embodiments, the foam or composite planar subsection of material can be preformed to include inner configured handholds, see further at  336  and  338  formed in representative tiles  328  and  330 , in order to facilitate ease of transport of the pallet. The grid supports  324  and  326  further depict underside extending stand-off locations, see at  340 ,  342 ,  344 , et seq. at both center and outer perimeter locations in order to establish dimensional stability to the assembly and to permit the configuration and dimensioning of respective pairs of interconnected side disposed and lift receiving apertures  314 ,  316 ,  318  and  320 . 
     Each of the outer frame defining members  306 - 312  and inner grid defining cross members  324  and  326  each exhibit a tight pattern of apertures, see at  346 ,  348 ,  350  et seq., which both serves to lighten the overall weight of the pallet as well as, in limited circumstances, to potentially communicate together all of the sections  328 - 334  during an associated in-fill process for introducing a flowable material into the section volumes in order to create a unitary pallet supporting surface. 
     Alternate to introducing pre-formed support sections (such as depicted at  282  in  FIG. 8 ) such an alternate application can contemplate an inter-filling material such as a structural foam, wood or composite thereof. Addition of underside supporting ledges (as shown at  300 ,  302  et seq. in  FIG. 8 ) can also be incorporated into the assembly of  FIG. 9  in order to provide underside load bearing support to such as pre-formed sections  328 ,  330  during subsequent installation. As with the previous embodiment, stackable upper edge protrusions/guides and inwardly stepped/notched underside locations are again provided for, as shown at  352  and  354  respectively for each individual structural member and in order to facilitate ease of stackability as previously described. 
     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.