Patent Publication Number: US-2015059624-A1

Title: Pallet

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a pallet, particularly to a pallet fabricated in an extrusion shaping method. 
     2. Description of the Prior Art 
     Pallets are designed for stacking cargos thereon and enable convenient movement and shipment. While a cargo is to be transported or lifted up, forks of a forklift are inserted into the underneath of a pallet where the cargo is stacked. Traditionally, pallets are made of wood. However, wooden pallets have some disadvantages. Fabricating wooden pallets are unfavorable to ecology because it consumes massive wood. Besides, wooden pallets are likely to spread pest insects because wood is likely to carry eggs of small pests, such as the pine wood nematodes ( Bursaphelenchus xylophilus ), which have endangered existence of forests globally. Thus, the international customs clearance of wooden pallets is very troublesome because it needs strictly quarantining beforehand. 
     On the other side, plastic pallets have been widely used. Plastic pallets are normally fabricated in an injection-molding technology. The molds thereof are very expensive. Besides, the fabrication efficiency is limited. 
     Therefore, it is a target to develop a pallet that can be fabricated easily and efficiently with less inexpensive molds. 
     SUMMARY OF THE INVENTION 
     The present invention proposes a pallet, which is fabricated with an extrusion shaping method in a continuous process, whereby the fabrication process is simple and economical. 
     In one embodiment, the pallet of the present invention comprises a first carrier board and a plurality of support elements. The first carrier board includes a first surface and a second surface opposite to the first surface. The support elements are arranged on the first surface of the first carrier board. Each support element has at least one first one through-hole penetrating the support element along a first direction, wherein the first direction is parallel to the first surface of the first carrier board. 
     Below, the embodiments are described in detail in cooperation with the attached drawings to make easily understood the objectives, technical contents, characteristics and accomplishment s of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing conceptions and their accompanying advantages of this invention will become more readily appreciated after being better understood by referring to the following detailed description, in conjunction with the accompanying drawings, wherein: 
         FIG. 1   a  and  FIG. 1   b  are perspective views respectively taken from different viewing angles and schematically showing a pallet according to one embodiment of the present invention; 
         FIG. 2   a  and  FIG. 2   b  are perspective views respectively taken from different viewing angles and schematically showing a pallet according to another embodiment of the present invention; 
         FIG. 3   a  and  FIG. 3   b  are perspective views respectively taken from different viewing angles and schematically showing a pallet according to yet another embodiment of the present invention; 
         FIG. 3   c  is a partial enlargement view schematically showing the connection of the first carrier board and the support element of the pallet shown in  FIG. 3   a  and  FIG. 3   b;    
         FIG. 3   d  is a perspective view schematically showing a pallet according to still another embodiment of the present invention; 
         FIG. 3   e  is a perspective view schematically showing a pallet according to a further embodiment of the present invention; 
         FIG. 4   a  and  FIG. 4   b  are perspective views respectively taken from different viewing angles and schematically showing a pallet according to a yet further embodiment of the present invention; 
         FIG. 4   c  is a partial enlargement view schematically showing the connection of the first carrier board and the support element of the pallet shown in  FIG. 4   a  and  FIG. 4   b;    
         FIG. 5   a,    FIG. 5   b  and  FIG. 5   c  are perspective views schematically showing pallets respectively according to several embodiments of the present invention; 
         FIG. 6  is a partial enlargement view schematically showing a pallet according to further another embodiment of the present invention; 
         FIG. 7   a  and  FIG. 7   b  are partial enlargement views schematically showing pallets respectively according to different embodiments of the present invention; and 
         FIG. 8  is a perspective view schematically showing a pallet according to further another embodiment of the present invention. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The detailed explanation of the present invention is described as follows. The described preferred embodiments are presented for purposes of illustrations and description, and they are not intended to limit the scope of the present invention. 
     Refer to  FIG. 1   a  and  FIG. 1   b  perspective views respectively taken from different viewing angles and schematically showing a pallet according to one embodiment of the present invention. The pallet  1  of this embodiment comprises a first carrier board  10  and a plurality of support elements  20 . The first carrier board  10  includes a first surface  11  and a second surface  12  opposite to the first surface  11 . The cargo is placed on the second surface  12 . The plurality of support elements  20  are arranged on the first surface  11  of the first carrier board  10 . Each support element  20  has at least one first through-hole  13   a  penetrating the support element  20  along a first direction X, wherein the first direction X is parallel to the first surface  11  of the first carrier board  10 . The support elements  20  contact the ground and support the first carrier board  10  and the cargo thereon. In this embodiment, the forks of a forklift are placed into the first through-holes  13   a  to lift up the pallet  1  and the cargo. 
     Refer to  FIG. 1   a  and  FIG. 1   b  again. One objective of the present invention is to provide an extrusion-shaped pallet. The pallet  1  of the present invention is continuously extrusion-shaped along the first direction X. The continuous fabrication process can form a continuous through-hole and support elements. The continuous support element can be easily cut into a plurality of support elements according to the required size. The shape or structure of the pallet can be easily changed via merely replacing the extrusion die of the extrusion-shaping system. Therefore, the pallet of the present invention can be flexibly fabricated to have diversified forms. Other embodiments of the present invention will be demonstrated below. 
     Refer to  FIG. 1   a  and  FIG. 1   b  again. In one embodiment, the plurality of support elements  20  is parallel arranged into two rows along the first direction X. Thereby, the forks of a forklift can be placed into the first through-holes  13   a  of the support elements  20 . 
     Refer to  FIG. 2   a  and  FIG. 2   b.  In one embodiment, the plurality of support elements  20  are parallel arranged into two rows along the first direction X and simultaneously parallel arranged into three rows along a second direction Y. Thereby, a pair of forks can be placed into the first through-holes  13   a  parallel to the first direction X, and a pair of forks can be placed between the support elements  20  parallel to the second direction Y. The first direction X is vertical to and coplanar with the second direction Y. Therefore, the application of the pallet  1  is free of directional limit, and the forks can be placed into the pallet  1  either along the first direction X or along the second direction Y. In this embodiment, the support elements  20  are arranged to form a 3×2 array, as shown in  FIG. 2   a  and  FIG. 2   b.    
     Refer to  FIG. 3   a  and  FIG. 3   b.  In one embodiment, the plurality of support elements  20  is arranged into three rows along the first direction X, whereby a pair of forks can be placed into the troughs between the support elements  20 . In the abovementioned embodiments, the forks are placed into the first through-holes  13   a.  In this embodiment, the forks may also be placed into the troughs between the support elements  20 . 
     Refer to  FIG. 3   a  and  FIG. 3   b  again. In one embodiment, the plurality of support elements  20  is arranged into three rows along the first direction X and along the second direction Y simultaneously, whereby a pair of forks can be placed between the support elements  20  either along the first direction X or along the second direction Y, and wherein the second direction Y is vertical to the first direction X. In this embodiment, the support elements  20  are arranged to form a 3×3 array, as shown in  FIG. 3   a  and  FIG. 3   b.    
     Refer to  FIG. 5   a.  In one embodiment, the second surface  12  of the first carrier board  10  is a flat plane. Refer to  FIG. 5   b.  In one embodiment, the carrier board  10  is a grid-like structure perforated from the normal direction Z of the first surface  11 , whereby the weight of the pallet  1  is reduced, and whereby the slip-proofness of the first carrier board  10  is enhanced. In one embodiment, the grid-like structure is not formed by the extrusion-shaping machine along the first direction X but formed by another machine from the normal direction Z. 
     Refer to  FIG. 6  a local perspective view schematically showing a pallet according to one embodiment of the present invention. In one embodiment, the pallet  1  further comprises a plurality of second through-holes  13   b  penetrating the first carrier board  10  along the first direction X. The second through-holes  13   b  can also save the material of the pallet  1  and reduce the weight of the pallet  1 . In one embodiment, the second through-holes  13   b  are formed via the extrusion shaping along the first direction X. 
     Refer to  FIG. 1   a,    FIG. 1   b,    FIG. 2   a,    FIG. 2   b,    FIGS. 3   a - 3   d,    FIG. 4   a,  and  FIG. 4   b.  In some embodiments, the first carrier board  10  includes a plurality of ribs  14  extending along the first direction X, which can enhance the mechanical strength of the first carrier board  10 . The ribs  14  are protruded or recessed from the second surface  12 . The present invention does not particularly limit the number or shape of the ribs  14 . In one embodiment, the ribs  14  are formed via the extrusion shaping along the first direction X. The ribs  14  are optional in the present invention. For example, the pallet  1  shown in  FIG. 3   a  has ribs  14 , and the pallet  1  shown in  FIG. 3   e  is free of ribs  14 . 
     Refer to  FIG. 5   c.  In one embodiment, the second surface  12  of the first carrier board  10  has a plurality of grooves  12   a  extending along the first direction X. The grooves  12   a  can increase the friction between the cargo and the second surface  12  of the first carrier board  10 , whereby the cargo is less likely to slip on the pallet  1 . In one embodiment, the grooves  12   a  are formed via the extrusion shaping along the first direction X. 
     Refer to  FIG. 5   c  again. In one embodiment, the pallet  1  further comprises a plurality of slip-proof pads or slip-proof patches (not shown in the drawings) arranged on the second surface  12  of the first carrier board  10 , whereby the cargo is less likely to slip on the pallet  1 . In one embodiment, the slip-proof pads or slip-proof patches are placed inside the grooves  12   a.    
     Refer to from  FIGS. 1   a  and  1   b  to  FIGS. 4   a  and  4   b.  In some embodiments, the support element  20  has at least one groove  12   b  formed on the outer surface thereof and extending along the first direction X. The outer surface of the support element  20  is opposite to the first surface  11  of the first carrier board  10 . The grooves  12   b  have a slip-proof function. In one embodiment, slip-proof pads or slip-proof patches (not shown in the drawings) are placed inside the grooves  12   b  to enhance the slip-proof effect. In one embodiment, the grooves  12   b  are formed via the extrusion shaping along the first direction X. 
     In one embodiment, the support element  20  has at least one slip-proof pad or slip-proof patch (not shown in the drawings) arranged on the outer surface thereof. The outer surface of the support element  20  is opposite to the first surface  11  of the first carrier board  10 . In one embodiment, the slip-proof pads are made of rubber. 
     Refer to  FIG. 3   d.  In one embodiment, the first carrier board  10  includes a plurality of openings  15  arranged on the second surface  12  for stacking the pallets  1 . The openings  15  of one pallet  1  can accommodate the support elements  20  of another pallet  1 , whereby the pallets  1  can be stacked one above one. 
     Refer to  FIG. 3   c.  In one embodiment, the first carrier board  10  is integrated with the support elements  20  to form a one-piece structure. In some embodiments, the first carrier board  10  and the support elements  20  are independent components. Refer to  FIGS. 4   a - 4   c.  In one embodiment, the first carrier board  10  has a plurality of first press-fit structures  10   a,  and each support element  20  has two second press-fit structures  20   a.  The second press-fit structures  20   a  are press-fitted to the first press-fit structures  10   a,  whereby one first carrier board  10  and a plurality of support elements  20  are assembled to form one pallet  1 . Therefore, the first carrier boards  10  and the support elements  20  can be separately fabricated in an extrusion-shaping method. Further, while the pallets  1  are not used, the first carrier boards  10  and the support elements  20  can be respectively stacked for storage, whereby a great amount of space is saved and the transportation of the pallets  1  becomes more efficient. 
     Refer to  FIG. 7   a  and  FIG. 7   b.  In one embodiment, the support element  20  has a connection structure  21  connecting the first carrier board  10  and the inner wall of the support element  20  to enhance the strength of the pallet  1 . Thereby, the pallet  1  can bear heavier cargo. 
     In the present invention, the pallet  1  is a single-carrier board structure or a double-carrier board structure. Refer to  FIG. 8 . In one embodiment, the pallet  1  further comprises a second carrier board  30  arranged on the other side of the support elements  20  and opposite to the first carrier board  10 . The second carrier board  30  covers the plurality of support elements  20 . Thereby, the cargo can be placed on either the top surface of the pallet  1  or the bottom surface of the pallet  1 . Thus, the application of the pallet  1  becomes more flexible. 
     The pallet  1  of the present invention may be a conventional plastic pallet. However, the pallet  1  of the present invention is preferably an environmental-protection pallet. In one embodiment, the pallet  1  comprises a plurality of strip-like fiber units, a filling material and a coupling agent. The strip-like fiber unit is made of wood powder, a plurality of crude rice husks or a combination thereof. The rice husks and wood powder are arranged along random direction of fiber axes thereof. A plurality of gaps is distributed among the wood powder and the rice husks. The filling material is filled into the gaps to bond the strip-like fiber units to form the appearance of a pallet. The coupling agent is distributed on the interface between the strip-like fiber units and the filling material to enhance the bonding between the strip-like fiber units and the filling material. In one embodiment, the strip-like fiber unit also contains wheat husks. 
     In one embodiment, the filling material contains at least one component selected from a group consisting of nylon, PP (polypropene), PE (polyethene), PVC (polyvinylchloride), and PET (polyethylene terephthalate). 
     In one embodiment, the coupling agent is selected from a group consisting of maleic anhydride grafted polyolefins, titanate coupling agents, and silane coupling agents. 
     In the abovementioned embodiments, the strip-like fiber units containing the crude rice husks and wood powder, the filling material and the coupling agent are bonded together to form the environmental-friendly pallet. The fiber of rice husks and wood powder can reinforce the pallet. Further, rice husks and wood powder are easy to source and able to reduce the consumption of wood and petrochemical materials. The environmental-protection pallet of the present invention has superior mechanical properties. Further, the environmental-friendly pallet of the present invention is water-proof, lightweight, easy to fabricate and exempt from insect pests. If the non-toxic material is used as the filling material, combustion of the environmental friendly pallets would not generate toxic gases. Furthermore, other materials may be added into the environmental-friendly pallet to diversify the application thereof. Besides, the broken or abandoned environmental-friendly pallets can be shattered and then recycled to fabricate new environmental-friendly pallets. Therefore, the environmental-friendly pallet of the present invention complies with the economical profit of material recycling. 
     In conclusion, the present invention proposes a pallet, which can be easily fabricated with an extrusion-shaping method in a continuous process. 
     The embodiments described are to demonstrate the technical thought and characteristics of the present invention to enable the persons skilled in the art to understand, make, and use the present invention. However, these embodiments are not intended to limit the scope of the present invention. Any equivalent modification or variation according to the spirit of the present invention is to be also included within the scope of the present invention.