Patent Publication Number: US-11643247-B2

Title: Wooden pallet with butted deck boards and metal bracket supports

Description:
RELATED APPLICATION 
     This application is a continuation of application Ser. No. 16/515,164 filed Jul. 18, 2019 which claims the benefit of provisional application Ser. No. 62/702,430 filed Jul. 24, 2018, which are hereby incorporated herein in their entirety by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to the field of pallets, and more particularly, to a wooden pallet having an improved resilience to impacts from material handling equipment. 
     BACKGROUND 
     Conventional wooden pallets include a base layer and a cargo layer separated by support blocks. The cargo layer traditionally has end deck boards assembled on connector boards that run the full length or width of the pallet. The end deck boards are nailed through the connector boards into the support blocks to build the primary structure of the pallet. The end deck boards are also known as lead boards. Intermediate deck boards are placed between the end deck boards. 
     To move the pallet with cargo thereon, forklift tines are inserted into the gaps between the base and cargo layers. If the forklift is not stopped in time, the forklift may crash into one of the end deck boards of the pallet. The end deck board may not be able to withstand such an impact over time. Accidents such as this weaken the pallet and greatly shorten the lifespan of the pallet, thereby causing the pallet to be repaired more frequently and/or removed from service long before its anticipated life cycle has been reached. 
     SUMMARY 
     A pallet includes a base layer, a cargo layer and a plurality of spaced apart supports coupled between the base and cargo layers and forming a gap therebetween for receiving a lifting member. The supports include outer corner supports each configured as a C-shaped bracket, and center supports each configured as a circular-shaped cylinder. Each center support includes an outer wall having opposing ends, a center hub having opposing ends, and a plurality of ribs extending between the center hub and the outer wall. 
     The opposing ends of the center wall may be aligned with the opposing ends of the outer wall. 
     The plurality of ribs may be recessed from opposing ends of the center hub and the outer wall. 
     The opposing ends of the outer wall may include a plurality of spaced apart drainage notches. 
     The plurality of ribs may be aligned with the plurality of spaced apart drainage notches. 
     The outer supports may comprise metal, and the center supports may comprise plastic. 
     The cargo layer may comprise a pair of spaced apart outer connector boards, at least one center connector board between the pair of outer connector boards, and a pair of spaced apart end deck boards on the pair of outer connector boards and the at least one center connector board. The end deck boards are orthogonal to the pair of outer connector boards and the at least one center connector board. 
     The cargo layer may further comprise a plurality of intermediate deck boards on the pair of outer connector boards and the at least one center connector board. 
     The base layer may comprise a pair of bottom end deck boards, and at least one bottom center deck board between the pair of bottom end deck boards. 
     The base and cargo layers may comprise wooden boards. 
     Another aspect is directed to a method for making a pallet as described above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a top perspective view of a wooden pallet with butted deck boards in accordance with the disclosure. 
         FIG.  2    is a bottom perspective view of the wooden pallet shown in  FIG.  1   . 
         FIG.  3    is a top view of the wooden pallet shown in  FIG.  1   . 
         FIG.  4    is a bottom view of the wooden pallet shown in  FIG.  1   . 
         FIG.  5    is a side view of the wooden pallet shown in  FIG.  1   . 
         FIG.  6    is an end view of the wooden pallet shown in  FIG.  1   . 
         FIG.  7    is a perspective view of one of the metal bracket outer supports shown in  FIG.  1   . 
         FIG.  8    is a perspective view of one of the plastic cylinder center supports shown in  FIG.  1   . 
         FIG.  9    is a perspective view of a wooden block support as an alternative to the supports shown in  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the particular embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout. 
     Referring to  FIGS.  1 - 6   , the illustrated wooden pallet  10  includes a base layer  20 , a cargo layer  30 , and a plurality of supports  40 ,  46  coupled between the base and cargo layers. The supports  40 ,  46  form a gap  50  between the base and cargo layers  20 ,  30  for receiving a lifting member, such as fork lift tines. 
     The cargo layer  30  includes a pair of spaced apart wooden end deck boards  32 , and a pair of wooden intermediate deck boards  34  between the end deck boards. More particularly, each end deck board  32  and an immediately adjacent intermediate deck board  34  are butted against one another. Pallet durability is significantly improved by having the end deck boards  32  butt up against the immediately adjacent intermediate deck boards  34 . 
     Also included within the cargo layer  30  is a pair of spaced apart wooden connector boards  36  and a wooden intermediate connector board  37 . The connector boards  36  and the intermediate connector board  37  are orthogonal to the end deck boards  32  and the intermediate deck boards  34 . The end deck boards  32  and the intermediate deck boards  34  are positioned on the connector boards  36 . 
     The base layer  20  includes bottom deck boards  22 ,  26  orientated in the same direction as the end deck boards  32  and the intermediate deck boards  34  in the cargo layer  30 . The bottom deck boards  22 ,  26  are directly coupled to the supports  40 ,  46 . 
     The supports include outer supports  40  and center supports  46  between the outer supports  40 . The outer supports  40  are configured as metal brackets having a C-shape or U-shape as illustrated in  FIG.  7   . The center supports  46  are configured as circular-shaped plastic cylinders as illustrated in  FIG.  8   . 
     Bolts are used to secure the supports  40 ,  46  to the corresponding boards in the base and cargo layers  20 ,  30 . A single respective bolt  63  is used for each support  40 ,  46  when securing to the cargo layer  30 . For the base layer  20 , a pair of respective bolts  63  is used for each outer support  40  and the same single respective bolt  63  is used for each center support  46  when securing to the base layer  20 . 
     For the metal bracket outer supports  40 , a single bolt opening  70  is in the cargo layer facing side, and a pair of bolt openings  72  is in the base layer facing side. For the plastic cylinder center supports  46 , a single bolt opening  80  is in the cargo and base layer facing sides. The plastic cylinder center support  46  includes a center hub  90  that includes the bolt opening  80 , and ribs  92  radially extending from the center hub  90  to an outer wall  94 . The ribs  92  may be recessed from opposing ends  47 ,  49  of the center hub  90  and the outer wall  94 . Notches or openings  95  are provided at the opposing ends  47 ,  49  to drain any liquids that may get inside of the plastic cylinder center support  46 . 
     As an alternative to the metal bracket outer supports  40  and the plastic cylinder center support  46 , wooden block supports  100  may be used as illustrated in  FIG.  9   . In other embodiments, wooden block supports  100  may be used to replace the outer supports  40  while the center supports  46  remain, or may be used to replace the center supports  46  while the outer supports  40  remain. 
     Nails  66  are used to couple adjacent boards together in the cargo layer  30 . The nails  66  are used to secure the end deck boards  32 , the intermediate deck boards  34  and additional intermediate deck boards  35  to the connector boards  36  and the intermediate connector board  37 . The nails may be clinched nails, particularly in the butted intermediate deck boards  34 . 
     The edges of each wooden support  100  may be angled or chamfered. The angled edges  102  may be within a range of about 25 to 75 degrees, for example, to deflect the impact force of the forklift tines should such an impact occur. The illustrated edges are angled at 45 degrees. 
     In the illustrated wooden pallet  10 , a size of each end deck board  32  and a corresponding intermediate deck board  34  butted thereagainst have the same dimensions. For example, a width of the end deck board  32  and the intermediate deck board  34  butted thereagainst may be 145 mm, for example. In another example, the width may be 78 mm. 
     In other embodiments, the size of each end deck board  32  and a corresponding intermediate deck board  34  have different dimensions. For example, the width of the end deck board  32  may be 78 mm and the width of the corresponding intermediate deck board  34  may be 98 mm. 
     Traditionally, the intermediate deck boards in wooden pallets have a width that is less than a width of the end deck boards. In addition, traditionally there is a gap between the end deck boards and the adjacent intermediate deck boards. In the illustrated wooden pallet  10 , pallet durability is significantly improved when there is no gap between the end deck boards  32  and the immediately adjacent intermediate deck boards  34 , particularly with the end deck boards  32  and the immediately adjacent intermediate deck boards  34  having a same width. 
     The cargo layer  30  also includes at least one additional intermediate deck board  35  positioned between the intermediate deck boards  34  that are butted against the end deck boards  32 . The additional intermediate deck boards  35  are positioned so that there is a gap between the adjacent intermediate deck boards  34 . The dimensions of the end deck boards  32  and the intermediate deck boards  34  as well as additional intermediate deck boards  35  positioned between the intermediate deck boards  34  are selected and spaced such that coverage of the cargo layer  30  is within a range of 70-85 percent of a maximum total surface area of the cargo layer  30  when there are no gaps between the boards. 
     A width of the intermediate deck boards  35  may be the same as a width of the intermediate deck boards  34  butted against the end deck boards  32 . Alternatively, in other embodiments, the intermediate deck boards  35  may have different widths. In addition, the boards making up the intermediate deck boards  35  may have different widths. For example, one of the intermediate deck boards  35  may have a width of 98 mm and another one of the intermediate deck boards  35  may have a width of 78 mm. 
     Another aspect is directed to a method for making a pallet  10  as described above. The method includes providing a base layer  20 , and providing a cargo layer  30 . The cargo layer  30  includes a pair of spaced apart outer connector boards  36 , and at least one center connector board  37  between the pair of outer connector boards  36 . A pair of spaced apart end deck boards  32  is on the pair of outer connector boards  36  and the at least one center connector board  37 , with the end deck boards  32  being orthogonal to the outer connector boards  36  and the at least one center connector board  37 . A pair of spaced apart intermediate deck boards  34  is on the pair of connector boards  36  and the at least one center connector board  37 , with the intermediate deck boards  34  being orthogonal to the outer connector boards  36  and the at least one center connector board  37  and butted against a respective end deck board  32 . 
     The spaced apart supports are coupled between the base and cargo layers  20 ,  30 . The supports include outer supports  40  and center supports  46 . The outer supports  40  are configured as a C-shaped bracket having an upper flange  41  contacting one of the outer connector boards  36  and a bottom flange  43  contacting the base layer  20 . The center supports  46  are configured as a circular-shaped cylinder having an upper surface  47  contacting the at least one center connector board  37  and a bottom surface  49  contacting the base layer  20 . 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.