Patent Abstract:
An easily assembled pallet, having two runners set apart and opposed, joists slidibly attached between the runners, and two retainers slidibly connected to each of the runners and contacting the joist end bottom surface thereby keeping the joists in proper location in the runners. Whereby the top of the joists forms the pallet&#39;s top flat surface. In addition, a support bar can be attached to the bottom of the joists between the runners to provide additional support and stiffness to the joists.

Full Description:
BACKGROUND OF INVENTION 
     The present invention relates to pallets, primarily to pallets that can be assembled and disassembled, and pallets moved by fork trucks. 
     Many products and goods are moved and stored on pallets. The majority of these pallets are constructed of wood and remain assembled after use because they cannot easily be taken apart. Other pallets constructed of plastic or paperboard cannot be disassembled at all. When not in use the pallets are usually stored and/or shipped back to their originator. Pallets, which cannot be collapsed or disassembled, require a large amount of space for storage and trucking. In addition, if a portion of the pallet is damaged, the whole pallet is discarded and a replacement procured. Space, material and time cost money to a business. Storage and transport of empty pallets has associated costs that can be reduced by keeping pallets unassembled while not in use. In addition, pallets constructed of matching parts and easily disassembled have the advantage of only requiring replacement of damaged parts. The pallet assembly also must not take a substantial amount of time to put together or take apart, the cost of which may be recovered from the savings in storing, return shipping, and replacement. 
     SUMMARY OF INVENTION 
     It is the intent of the present invention to provide an easily assembled and disassembled pallet manufactured of plastic or other suitable material and constructed of a number of specific parts. The pallet would be delivered to a user in the unassembled form. Varying the lengths of associated parts will also make pallets of different sizes. 
     The general purpose of the present invention is a pallet assembly can easily be assembled and unassembled. 
     It is an object of the present invention to have the storage of the pallet in an unassembled form thereby requiring less space for storing and shipping. Smaller trucks may be used to transport the pallets; or more can be transported in the same size truck. 
     Another object of the present invention is to provide a versatile pallet by varying the sizes of associated parts and not requiring a separate top sheet. 
     A further object of the present invention is to provide like parts for all pallets of the same size and load rating. Which allows easy replacement of damaged parts. 
     Another object of the present invention is to enable the assembly or disassembly to be accomplished within a few minutes without tools. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     All 8 views are viewed from the same direction. 
     FIG. 1 is a perspective rendition of the completely assembled pallet. 
     FIG. 2 is a perspective rendition of the runners. 
     FIG. 3 is a perspective rendition of the joist. 
     FIG. 4 is a perspective rendition of the retainer bar. 
     FIG. 5 is a perspective rendition of the support member. 
     FIG. 6 is a perspective rendition of the end fastener. 
     FIG. 7 is a perspective rendition of the support member and end fastener. 
    
    
     DETAILED DESCRIPTION 
     FIG. 1 shows a perspective of a completed easily assembled pallet having two opposed and parallel runners  1 , at least one joist  2  connected at either end to runners  1 , two retainer bars  3  one each inserted in runners  1  to hold the joists  2  in place vertically so that a flat surface is formed by the top surfaces of the runners  1  and joists  2 . At least one support member  4  to provide additional strength and support for joists  2 , and two end fasteners  5  to hold the support member  4  in place (only one end fastener is visible in this figure). The parts of the pallet may be constructed of different types of plastic, any other suitable material, or a combination of materials. The material used needs to be selected for required strength, resiliency, and durability, ease of manufacture, cost, and other such considerations. The height of the runners  1  and support member  4  are such that forks of a lift truck will easily slide below the joists  2 . And, the spacing apart of runners  1  and support member  4  is such that a lift truck fork will pass between the support member  4  and runner  1 . The support member  4  may not be required for light loading or small pallets. 
     A pair of runners  1  is shown in FIG.  2 . For a given pallet size the runners are made identical in size and with the same number and spacing of keyways  7  so that they may be used interchangeably on either side. The at least one keyway  7  are formed as part of, or affixed to, the runner  1 , and spaced such that there is minimal spacing between joists  2 . The keyway  7  is shown as “T” shaped as can be seen in the enlarged view but can be any number of shapes. The keyway  7  contacts the inside surface of runner side  10 . The top of the keyway  7  is also in contact with the runner top underside  11  of the runner  1 . Depressor  6  is formed as part of, or affixed to, runner bottom  12 . Depressor  6  is sloped to aid the placement of retainer bar  3  and to hold retainer bar  3  in place when assembled. To allow depressor  6  to be retractable from the retainer bar  3  during assembly and disassembly, slots are cut into runner bottom  12  along each side of depressor  6 . A spring-loaded depressor  6  could be used if the runner material is inelastic. Slot  8  is cut completely through each of ends  13  and  14 . Hole  9  is cut through surface  10 , aligned with and above depressor  6 . 
     FIG. 3 shows a joist  2  with ends  15 , flanges  16  and  17 , and web  18 . At least one joist  2  is required when assembling a pallet. The joist end  15  is a key shown in the shape of a “T” matching the runner keyway  7  so the joist end  15  can be slip fit into the runner keyway  7 . The joist top flange  16  is shorter on each end than the bottom flange  17  by an amount to allow the top flange to fit between the runner top surfaces  11 . Thus, the length of the joist top flange  16  is limited to the spacing of the runners  1 . This allows all top surfaces of the pallet to be flush and a tight fit can occur between the ends of flange  16  and runner top  11 . If a tight fit is not required the top flange  16  length can be shorter. The end  15  is flush with the end of the bottom flange  17 . When joist end  15  is inserted into runner keyway  7 , joist end  15  and the end of flange  17  are to fit tightly against runner inside surface  10 . Each end of the joist  2  are constructed the same so the joist  2  can be inserted into either runner  1 . The joist  2  so installed forms the top surface of the pallet, therefore, no top sheet is required for a continuous surface. If a contiguous top pallet surface is not required some joists  2  can be left out of the assembly. 
     FIG. 4 shows in detail one retainer bar  3  having tongue ends  19 , recess  20 , top surface  24 , bottom surface  25 , front surface  26 , and back surface  27 . The retainer bar  3  must be flexible to allow a slight bending to take place during assembly. The overall length of retainer bar  3 , including the two tongue ends  19  is the same length as runner  1  overall length from outside runner surface  13  to outside runner surface  14 . Retainer bar  3  fits inside runner  1 . Runner slot  8  and tongue  19  are of substantially the same size and shape with runner slot  8  being slightly larger to allow a slip fit with tongue  19 . Recess  20  is provided for clearance of runner depressor  6  with additional finger clearance for removal of retainer bar  3  during disassembly. To avoid having to bend the retainer bar  3  the tongue ends  19  could be replaced with spring loaded tongues or pins; or the ends could be without tongues and held in place with screws or clamps. 
     FIG. 5 shows the support member  4  having a top surface  30 . At each end of the support member  4  is formed a hole  31  and a slot  32  which is tapered from inside adjacent hole  31  towards the support member  4  free end as can be seen in enlarged view of FIG. 5 (Top portion above slot of support member  4  is shown removed for clarity). The height of slot  32  is the same as the diameter of hole  31 . 
     FIG. 6 is a detail of the end fastener  5 . The end fastener  5  has two pins  33  formed as part of, or attached to, and extending from the inside surfaces of end fastener  5  having a clearance between the free ends of pins  33  slightly larger than the small end width of the support member tapered slots  32  or the thickness of the support member between the end depth of the holes  31 . The height of pins  33  are slightly less than the height of the support member slot  32  and hole  31  to allow the pins  33  to slide within the slot  32  and engage the hole  31 . The pins are shown round but any suitable shape can be used. Spring-loaded pins can be used if material is inelastic. A pin can be construed to mean a dowel, rod, bar, dimple, nipple, or the like. Slot  38  of end fastener  5  is of size and shape to fit over joist flange  17 . The bottom of slot  38  is on the same plane as the top of support member  4 . The end fasteners  5  when pushed into place engaging a support member  4  and joist flange  17  will lock the support member  4  to the bottom of joist  2  as shown in FIG.  1 . Many other means of fastening the end fastener  5  to the support member  4  can be contrived which may or may not require the use of tools. Such as, drilling holes in the end fastener sides and through the support member  4  ends then passing a bolt through and securing with a nut. 
     FIG. 7 shows the end fasteners  5  mounted on the support member  4 . 
     Assembly and disassembly does not require any tools. 
     To assemble, set two runners  1  on a flat surface nearly parallel with inside surfaces facing each other. Insert a joist end  15  into an end slot  7  of one runner  1 , next insert the opposite joist end  15  into the end slot  7  of the second runner  1 . Similarly insert a second joist  2 , if required, at the opposite end of the runners forming a rectangular shape. Continue inserting additional joists as needed until the required number of slots  7  are connected between the two runners  1 . 
     After all the joists  2  are installed in runners  1 , the retainer bar  3 , with front surface  26  facing toward the inside of the pallet, is installed by inserting one tongue  19  into runner end  13  slot  8 . With the one tongue  19  inserted in a runner slot  8 , the retainer bar  3  is slightly bent until the retainer bar clears the runner end  14  allowing the free end tongue  19  to be inserted in the adjacent runner slot  8 . As the tongue  19  enters runner slot  8  in runner end  14 , apply pressure to retainer bar surface  26  (thereby causing depression of depressor  6 ) until surface  26  clears runner depressor  6 . Runner depressor  6  moves back up to original position when retainer bar  3  is in place, thereby locking retainer bar  3  in place within runner  1 . When retainer bar  3  is in the assembled position the retainer top surface  24  fits tightly against the bottom surface of joist bottom flange  17 . Repeat the procedure to install the second retainer bar  3  on the opposite side of the pallet. 
     When the runners  1 , required joists  2 , and retainer bar  3  are in place the support member  4  with two end fasteners  5  can be installed. The support member  4  is set in place at approximately the center of the pallet, parallel to runners  1 , and against joist bottom flange  17 . The two end fasteners  5  are next installed one at each end of support member  4 . As the end fastener  5  is pushed into place, the sides having the pins  23  attached bend outwardly, distorting until pins  33  reach hole  31  thereby sliding into hole  31 . At the same time slot  38  of end fastener  5  slides over and encompasses flange  17 . After repeating this procedure with the second end fastener  5  the support member  4  is locked in place with the two end joists  2  and the support member top surface  30  is flush with the bottom of joist flange  17 . Repeat if additional support members are required. Support member  4  is used when additional support of joists  2  is needed. When assembled the bottom of the support member  4  is on a parallel plane with the bottom of runners  1  (all 3 sit flat and touch the floor). 
     Disassembly is accomplished in reverse order of assembly. Remove support member end fasteners  5  by slightly spreading the sides apart and sliding the end fasteners  5  off. Then remove the support member  4  (repeat for additional support members). Remove the retainer bar  3  by applying pressure to runner depressor  6  and to retainer bar back surface  27  by pushing through runner hole  9  causing the retainer bar  3  to bend releasing tongues  19 . Repeat this procedure to remove the second retainer bar  3 . The joists  2  can now be easily removed from the runners  1 . 
     Assembling and disassembling would be easier with the pallet upside down with top of the pallet resting on a flat surface. 
     The phrase “formed as part of” as used herein applies to the use of a material where pieces can be manufactured as one piece. If the material used does not allow forming of parts then some attachment means can be substituted such as welding, screwing, bolting, clamping or the like. 
     While a preferred form of the invention has been shown in the drawings and described, since variations in the preferred form will be apparent to those skilled in the art, the invention should not be construed as limited to the specific form shown and described, but instead is as set forth in the following claims.

Technology Classification (CPC): 1