Abstract:
A convertible pallet alternately displays and ships/transports associated product received thereon is disclosed herein. The pallet includes a substantially planar support member for receiving the associated product thereon. At least first and second wheels are mounted to the pallet. A convertible support surface is movably mounted to the pallet, the convertible support surface having (i) a first position where the convertible support surface receives loads imposed on the upper surface and transfers the loads directly to an associated surface, and (ii) a second position where the wheels extend outwardly from the lower surface for engagement with the associated surface so that loads imposed on the upper surface are transferred to the associated surface through the wheels and for converting the pallet into a movable cart.

Description:
[0001]    This application claims the priority benefit of U.S. provisional application Ser. No. 62/020,879, filed Jul. 3, 2014, the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates to an apparatus and method for facilitating transport of product, such as bottled milk. More particularly, the disclosure relates to a convertible pallet used to support a stacked array of product on an upper surface thereof whereby the pallet may be selectively lifted, for example by a lift assembly such as a forklift or pallet jack, so that the pallet can be converted from a stationary pallet to a movable pallet, or vice versa, and allow product supported on the pallet to be easily shipped, transported through a store, and positioned in a display area. The disclosure may find application in related environments and applications. 
         [0003]    It is now common to package bottled milk on pallets, either with or without milk crates or containers. However, it is difficult to use and move a fully loaded pallet with, for example,  270  milk bottles, through the store because of the footprint associated with the full pallet. Many stores do not use motorized forklifts because of the size, noise, and smell associated with use of a forklift in a store environment. Likewise, lifting and transporting loaded pallets with a pallet jack through the store still does not overcome the size constraint issue. 
         [0004]    Consequently, many stores still desire to transport milk delivered from the dairy plant on bossies. A bossy is a frame-like structure having two or more caster wheels for ease of movement in the store. The bossy has a smaller footprint than a full pallet unloaded from the transport trailer into the back room of the store, and then manually pushed around the store from the back room storage area to the display case. Typically, the bottled milk is left on the bossy in the display case so that approximately 80 gallons of bottled milk are available on a single bossy in the display case. 
         [0005]    When used in this manner, the empty bossies still need to be returned or shipped back to the dairy plant, the bossies need to be cleaned, and special loading equipment is required for loading and unloading empty bossies onto trucks. Bossy carts are expensive (typically constructed from stainless and may cost approximately $750 each), and heavy (may weigh on the order of 200 to 300 pounds each when empty). 
         [0006]    Alternatively, pallets of bottled milk are unloaded from a truck into a back room, and the bottled milk is sometimes manually transferred from the pallets to a bossy in the store back room. Even though the bossy contains multiple shelves, it takes three or more trips to transport the bottled milk stored on a full pallet (224 bottles) on a bossy (that stores 80 gallon or 3 liter bottles) to a retail store display where the bottled milk is accessed by the consumer. 
         [0007]    As will be appreciated, a need exists for improving transport of product such as bottled milk from a dairy, to a back room of a store, and to the display case. 
       SUMMARY OF THE DISCLOSURE 
       [0008]    A convertible pallet for alternately displaying and transporting associated product received thereon is disclosed herein. The pallet includes a substantially planar support member having an upper surface for receiving the associated product thereon and a lower surface configured to receive an arm from an associated lift assembly. At least first and second wheels are mounted to the lower surface. A convertible support surface is movably mounted to the pallet, the convertible support surface having (i) a first position where the convertible support surface receives loads imposed on the upper surface and transfers the loads directly to an associated surface, and (ii) a second position where the wheels extend outwardly from the lower surface for engagement with the associated surface so that loads imposed on the upper surface are transferred to the associated surface through the wheels and for converting the pallet into a movable cart. 
         [0009]    The convertible support surface includes a hinge mounting assembly for selectively pivoting the convertible support surface relative to the support member. 
         [0010]    The hinge mounting assembly includes a retaining member for holding the convertible support surface in one of the first and second positions. 
         [0011]    The hinge mounting assembly includes a slot on one of the planar support member and convertible support surface, and extension member on an other of the planar support member and convertible support surface and selectively received in the slot. 
         [0012]    The retaining member includes one of a threaded member or a biased member for tightening the convertible support surface to the planar support surface. 
         [0013]    The convertible support surface includes first and second flanges hingedly mounted on opposite ends of the planar support member. 
         [0014]    In the first position, the flanges are disposed in substantially parallel relation with the upper surface of the planar support member. 
         [0015]    In the first position of the flanges, the wheels are located between the flanges and the planar support member. 
         [0016]    In the first position, the flanges are disposed beneath the wheels. 
         [0017]    In the first position of the flanges, the wheels are located between the flanges and the planar support member. 
         [0018]    In the second position, the flanges extend substantially perpendicular to the upper surface of the planar support member. 
         [0019]    In the second position of the flanges, the wheels extend outwardly from the planar support member a greater distance than the flanges. 
         [0020]    A method of transporting milk includes providing a pallet configured to receive an arm from an associated lift assembly. At least first and second wheels are selectively mounted on the pallet. A convertible support member has a first position where the convertible support member extends from the pallet and transfers load forces on the pallet directly to an associated surface, and a second position where the support member is moved out of the way and the wheels engage the associated surface so that loads imposed on the upper surface are transferred to the associated surface through the wheels and for converting the pallet into a movable cart. 
         [0021]    The method further includes loading milk bottles in a stacked array on the pallet with the convertible support member in the first position. 
         [0022]    The method further includes wrapping the stacked array of milk bottles on the pallet. 
         [0023]    The method includes positioning the convertible support member to the second position so that the pallet with milk bottles stacked thereon may be transported on the pallet wheels without removal from the pallet. 
         [0024]    The method includes using a lift assembly to raise the pallet from the associated surface and thereby change a position of the convertible support member from one of the first and second positions to the other of the first and second positions. 
         [0025]    The method further includes providing shelves above the loaded pallet in a display case. 
         [0026]    A primary benefit of the present disclosure relates to improved movement of product through a store. 
         [0027]    Another advantage resides increased efficiencies associated with the convertible pallet. 
         [0028]    Still another benefit is associated with the ability to use the same assembly to ship, transport, and display product. 
         [0029]    Still other benefits and advantages of the present disclosure will become more apparent from reading and understanding the following detailed description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]      FIG. 1  is a perspective view of a preferred embodiment of a convertible pallet. 
           [0031]      FIG. 2  is a plan view of the convertible pallet of  FIG. 1 . 
           [0032]      FIG. 3  an elevational view of the convertible pallet taken generally from the left-hand end of  FIG. 2 . 
           [0033]      FIG. 4  an elevational view of the convertible pallet taken from the front of  FIG. 2 . 
           [0034]      FIG. 5  is a perspective view of the underside of the convertible pallet with one end in a first, stationary position and the other end in a second, movable position. 
           [0035]      FIG. 6  is an enlarged view of a roller/wheel disposed on the flange disposed in a horizontal position. 
           [0036]      FIG. 7  is an enlarged elevational view of a roller/wheel with the flange oriented in a vertical position. 
           [0037]      FIG. 8  is a perspective view of the convertible pallet loaded with product such as a stacked array of milk bottles. 
           [0038]      FIG. 9  is an end view of the loaded convertible pallet of  FIG. 8 . 
           [0039]      FIG. 10  shows a display case with bossies illustrated at one end and use of the convertible pallet for displaying product adjacent thereto. 
           [0040]      FIG. 11  is a perspective view of the display case taken generally behind the display wall. 
           [0041]      FIG. 12  is a perspective view of a support assembly used in association with the convertible display pallet. 
           [0042]      FIG. 13  is a perspective view of a convertible pallet generally illustrating an underside thereof. 
           [0043]      FIG. 14  is a bottom plan view of the convertible pallet of  FIG. 13 . 
           [0044]      FIG. 15  is an elevational view of the convertible pallet taken generally along the line  15 - 15  of  FIG. 14 . 
           [0045]      FIG. 16  is an elevational view taken generally along the line  16 - 16  of  FIG. 15  (i.e. from the right-hand end of  FIG. 15 ). 
           [0046]      FIG. 17  is a cross-sectional view taken generally along the line  17 - 17  of  FIG. 14 . 
           [0047]      FIG. 18  is an enlarged view of the encircled region of  FIG. 17 . 
           [0048]      FIG. 19  is a cross-sectional view taken generally along the line  19 - 19  of  FIG. 14 . 
           [0049]      FIG. 20  is an enlarged view of the encircled region of  FIG. 19 . 
       
    
    
     DETAILED DESCRIPTION 
       [0050]    Turning to  FIGS. 1-5 , there is shown a convertible pallet  100  that includes a support surface  102 , shown here as having a generally rectangular conformation. In one embodiment, the support surface  102  has perimeter dimensions that closely approximate one-half the surface area of a conventional pallet for reasons which will become more apparent below. However, this does not preclude other conformations or dimensions that may find particular application within the dairy/store industry or use outside of the dairy industry. The support surface  102  forms a rigid planar surface adapted to receive product (as will be discussed further below with respect to bottled milk) on the surface. As is known, the product can be arranged in a stacked array on the support surface in a manner generally shown and taught in commonly owned U.S. Pat. Nos. 6,068,161 and 6,591,986, the disclosures of which are expressly incorporated herein by reference. 
         [0051]    A convertible support surface is provided on the pallet, namely, at first and second ends  104 ,  106  of the support surface  102  are provided selectively movable flanges or slats  110 . Since each flange  110  is preferably the same design and construction, description of one flange is equally applicable to the other. The flange  110  is mounted to the support surface  102  for movement between first and second positions. A first or support position is shown at the left-hand end  104  in  FIG. 1  as a generally horizontal orientation where the flange is positioned beneath rollers or wheels  120 . In this first position, the convertible support surface or flange  110  receives loads imposed on the upper surface of the pallet and transfers the loads directly to an associated surface (ground or floor). In a second position shown at the right-hand end  106  of  FIG. 1 , the convertible support surface or flange  110  is disposed in a generally vertical orientation extending downwardly from the support surface  102  but having a dimension whereby the flange in the second position terminates above the lowermost surface of the wheel  120 . In this manner, when both flanges  110  are disposed in the first, storage position, the pallet  100  is stationary and is used in substantially the same manner as a conventional pallet (i.e., it supports product on the upper surface and loads are transferred to the floor or ground surface). When both flanges  110  are oriented in the second, movable position, the pallet  100  is transformed into a wheeled support cart so that product stored thereon can be easily moved (i.e., rolled) over the ground surface. 
         [0052]    Each wheel  120  may be a fixed axis or a caster-type wheel that can rotate about a vertical axis in a manner well known in the art. For example, each wheel  120  is mounted for rotation about a horizontal axis or axle  122  supported by first and second support arms  124 . Generally speaking, the wheel structure and operation (whether it be a fixed axis or caster-type wheel) is conventional so that further discussion is deemed unnecessary to a full and complete understanding of the present disclosure. 
         [0053]    To reposition the flanges  110  between the first and second positions, and vice versa, the entire pallet  100  is raised off the ground surface. For example, a conventional lift assembly such as a forklift or pallet jack (not shown) is used. A support arm(s) such as tines or forks of the lift assembly are advanced beneath the support surface  102  between the ends  104 ,  106  and the entire pallet  100  raised a predetermined height off the ground. That predetermined height is sufficient to allow the orientation or position of the flanged is  110  to be advantageously changed from the first (support) position to the second (movable) position, and vice versa. The forklift or pallet jack are not shown, however they are conventional structures that are well known to one of ordinary skill in the art. 
         [0054]    As perhaps best illustrated in  FIG. 5 , an underside  130  of the support surface  102  may be reinforced with one or more ribs or reinforcing members  132  to provide added strength to the pallet  100 . Preferably, the reinforcing members  132  have a minimal height so as not to interfere with the orienting or operation of the flanges  110  in the second or vertical position. 
         [0055]    Once the flanges  110  are oriented in the same manner, i.e. either in the horizontal, storage position or in the vertical, movable position, the pallet  100  is lowered so that the pallet is either stationary (when the flanges are in the horizontal/storage position) or the pallet is movable (when the flanges are in the vertical/movable position). 
         [0056]    With continued reference to  FIGS. 1-5 , and additional reference to  FIGS. 6 and 7 , one preferred design structure or assembly for alternate positioning of the flanges  110  is shown. Particularly, an orienting plate(s)  140  is provided on the flange  110  and the plate includes an elongated groove  142  that receives a guide pin  144  that has a reduced diameter stem portion  146  and an enlarged head  148  ( FIG. 6 ). The stem portion  146  cooperates with the plate  140  and limits the rotational movement of the flange  110  along the path defined by the groove  142 . The head  148  of the pin  144  retains the plate  140  in position (e.g., the retaining member includes one of a threaded member or a biased member for tightening the convertible support surface to the planar support surface). Thus as shown in  FIG. 7 , the pin  144  is disposed adjacent one end of the groove  142  to maintain the flange  110  in the vertical position so that the wheels  120  engage the ground surface and the pallet  100  can be maneuvered. In the orientation shown in  FIG. 6 , on the other hand, the pin  144  is disposed in the other end of the slot  142 , and preferably along shoulder  150  ( FIG. 7 ) to orient the flange  110  in the first, storage position beneath the wheel  120  whereby the pallet  100  is stationary. Abutment between the pin  144  and the shoulder  150  in the orienting plate  140  prevents inadvertent movement of the flange  110  and ensures the user that the flange has been properly positioned. 
         [0057]    In addition, a finger  152  and recess or groove  154  are provided to also aid in holding the flange in the vertical orientation (see  FIG. 7 ). 
         [0058]      FIGS. 8 and 9  show products  160  stacked on the pallet  100 . Specifically, product shown here is bottled milk, for example, in stackable bottles of the type shown and described in the commonly owned, referenced patents. Here, each layer holds fifty six bottles on a pallet  100  that is dimensioned as a one-half conventional pallet. Since there are four layers, a total of two hundred twenty four milk bottles are received on the pallet. The entire stacked array may be held together by a plastic wrap or otherwise conveniently held together in some other manner. Because the aisles and room to maneuver in a retail store can be limited, it is undesirable to transport an entire pallet with stacked product thereon through the store. 
         [0059]      FIGS. 10-12  illustrate some of the advantages of the convertible pallet  100 . Namely, bossies are usually transported into position that the display case (left-hand end of the display shown in  FIG. 10 , or at the right-hand end when viewed from the rear of  FIG. 11 ). Even when fully loaded, an individual bossy only carries eighty, one gallon or three liter bottles whereas the convertible pallet shown in  FIG. 8  carries twenty-eight filled bottles in each layer for a total of one hundred twelve filled bottles with four layers disposed on the illustrated convertible pallet  100 . Thus, substantially more product  160  can be conveniently transported and displayed. Moreover, the bossy has a greater height than the corresponding half pallet  100 . Thus, additional display shelving or product storage can be provided over the convertible pallet. Less trips are required to transport product to the display. Less trips are required to remove the empty pallet  100  than would be required for the same number of product if the bossies are used. Other product can be conveniently displayed over the pallet  100  in shelving  170  ( FIGS. 10-12 ). Further, no specialized equipment for handling the bossies, all at a reduced cost to manufacture, clean, replace, etc. in addition, the convertible pallets  100  may be stacked one atop another when there is no product supported thereon. 
         [0060]      FIGS. 13-20  illustrate a slightly different version of a convertible pallet of the present disclosure. For ease of description and understanding, like reference numerals in the “ 200 ” series will be used to describe like components, e.g convertible pallet  100  in  FIGS. 1-12  will now be described as convertible pallet  200  in  FIGS. 13-20 , and new reference numerals will describe new components. The convertible pallet  200  has a planar support surface  202 . Again, the convertible pallet  200  is shown as having a generally rectangular or square configuration, although other configurations or dimensions may be used without departing from the scope and intent of the present disclosure. The support surface  202  may be formed of a rigid and lightweight material such as aluminum and may have a corrugate construction for added strength and rigidity (see corrugate bottom of support surface in  FIG. 13 ) and/or may include an additional lateral support member  208  for stability. 
         [0061]    Opposite ends  204 ,  206  of the convertible pallet  200  include selectively movable flanges  210 . Each flange  210  may be individually pivoted through approximately 90° when the convertible pallet  200  is raised from the floor by a lift assembly (not shown). Central openings  212  are provided in each of the flanges  210 , and each flange is centrally mounted to a support structure  214  that extends from an underside of the support surface  202  for rotation through approximately ninety degrees between the horizontal and vertical positions. A first or support position (horizontal) of the flange  210  is shown on the right-hand side of  FIGS. 13-15 and 17 , while the second or movable position (vertical) of the flange is illustrated on the left-hand side of these figures. When the flanges  210  are in the first or support position, loads are transferred from the support surface  202 , through the support structure  214 , and to the flanges  210  which are supported on the ground or floor surface. On the other hand, when the flanges  210  are oriented in the second or movable position, loads are transferred from the support surface  202  to the wheels  220  which are free to roll along the ground or floor surface. 
         [0062]    Rotatable, caster wheels  220  are also mounted to an underside of the support surface  202 . As noted in the prior embodiment, preferably each wheel  220  can rotate relative to the support surface  202  about a vertical axis in a manner well known in the art for ease of steering and maneuverability of the convertible pallet  200 . 
         [0063]    To reposition the flanges  210 , a lift assembly (not shown) such as a forklift, pallet jack, etc. has support arms that can be advanced beneath the support surface  202  whereby the convertible pallet  200  can be raised or lowered relative to the ground or support surface. In the raised position of the convertible pallet  200 , an operator can then manually rotate the flanges  210  to the other position, and then the support arms lowered to lower the convertible pallet  200  as needed so that the pallet is either stationary (when the flanges are in the horizontal/storage position) or movable (when the flanges are in the vertical/movable position). 
         [0064]    As perhaps best represented in  FIG. 17 , a pair of pins  244  cooperate with associated slots or grooves  242  associated with the support structure  214  of the flanges. The grooves  242  include stop positions at either end to receive pins  244  and orient the associated flanges  210  between the vertical and horizontal positions i.e., the first and second positions of the flanges. 
         [0065]    As will be appreciated, in the production environment, when the convertible pallet  200  is used primarily in the pallet (stationary) mode, the floor surfaces are typically not as smooth and the wheels  220  would be subject to degradation. Thus in the production plant, it is likely that the flanges  210  would remaining in the horizontal position and any movement of the convertible pallet  200  with or without loads thereon would be such as to protect the wheels  220  from harsh handling or traffic. On the other hand, in the retail environment where the floors are generally smoother, the flanges  210  would be rotated to the vertical, movable position and the convertible pallet  200  (either loaded or unloaded) could be easily rolled across the floor surface. This adds substantial useful life to the pallet  200  since the wheels  220  are primarily exposed to use only in those environments with smooth floors. 
         [0066]    This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and/or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and/or steps and combinations of claims during prosecution.