FIELD OF THE INVENTION

The present invention relates to a pallet used for supporting and transporting a load, and a method for manufacturing same.

BACKGROUND OF THE INVENTION Pallets are widely used for transporting goods or other loads, and are typically constructed from wood and/or metal. However, the use of metal/wood suffers from cost and/or environmental issues.

SUMMARY OF THE INVENTION Accordingly, it is an object of the invention to provide a pallet that is low cost and environmentally friendly (e.g. using recyclable materials).

In accordance with one aspect of the invention, there is provided a pallet comprising: a plurality of frames, each having at least one frame- support connecting member; at least one frame-support member, connected to the frame at the frame's frame-support connecting member; a strengthening layer substantially covering at least a connection point between the at least one frame and the at least one frame-support member; and at least one frame interconnecting member whereby the plurality of frames are interconnectable and the strengthening layer substantially covers interconnections between the frames.

In another aspect of the present invention, a method of producing a pallet is provided. The method includes the steps of: providing a plurality of frames; forming inter-connections between at least one frame-support member and each frame of the plurality of frames, to form an assembly; placing the assembly into a mold of an injection molding apparatus; injecting a polymer into the mold, thereby covering at least the interconnections between the plurality of frames and the plurality of frame- support members ; and curing the polymer, whereby the inter-connections are substantially covered with a polymer strengthening layer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be understood upon reading of the following detailed description of non-limiting exemplary embodiments thereof, with reference to the following drawings, in which:

Fig. IA is a perspective view of an embodiment of a skeleton of a sub-unit of the pallet of the present invention;

Fig. IB is an enlarged view of area A of Fig. IA; Fig. 2 A is a perspective view of a pallet skeleton formed of the sub- units of Fig. IA;

Fig. 2B is an enlarged view of area B of Fig. 2A; Fig. 3 is an embodiment of a pallet of the present invention; and Fig. 4 is a flow chart process for producing a pallet of the present invention.

The following detailed description of the invention refers to the accompanying drawings referred to above. Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Referring first to Figs. IA and Fig. IB, there is shown a skeleton of a sub-unit of a pallet comprising a frame 10 and four frame-support members, for example feet 12, generally at the corners of the frame.

Frame 10 is substantially rectangular, generally constructed of horizontal and vertical beams. Frame 10 typically also includes diagonal structural beams 11. In addition, frame 10 has three frame attaching corners 14, 16, 18, and one ending corner 20. Each of the frame attaching corners 14, 16, 18 has joining members 22, 24, 26, 28, 30 and 32 intended for interconnection to other like frames (Fig. 2A).

As seen more clearly in Fig. IB, each of the joining members 22, 24, 26, 28, 30 and 32 has a plurality of feet connecting members, for example in the form of "T" shaped protrusions 34 and generally one frame interconnecting member, illustrated by "T" shaped protrusion 36. Ending corner 20 is not connected to another frame, rather it is only connected with foot 12, and therefore ending corner 20 has only feet connecting members ("T" shaped protrusions 34). The top surface of each frame-support member or foot 12 comprises a frame matching groove 38 having frame connecting recesses 40 corresponding to joining members 22, 24, 26, 28, 30 and 32, and upon which corners 14, 16, 18 and 20 of frame 10 is snugly laid. Feet 12 of frame 10 are spaced apart from one another at a distance corresponding to one or more prongs of a conventional forklift.

Figs. 2A and 2B show an assembly of corresponding four frames 10 forming a pallet in accordance with an embodiment of the present invention. The four corresponding frames 10 are snapped together and connected to nine feet 12. As seen more clearly in Fig. 2B, each interconnectable corner of frame 10 is snuggly nested within a corresponding groove 38 of feet 12 within corresponding "T" shaped protrusions 34.

It should be noted that, in other embodiments of the present invention the frames 10 can be assembled in various configurations and numbers, mutatis mutandis. Accordingly, the number of support feet 12 can vary and is not restricted to a certain number. If implemented using only one foot 12, the foot is could be a single broad foot generally in center of frame 10.

Fig. 3 depicts an exemplary pallet of an embodiment of the present invention. The pallet is produced by covering the assembly of frames 10 and feet 12 (seen in Fig. 2A) with a polymeric covering, in particular, covering at least the interconnection points between interconnected frames

10 and/or connection points between frames 10 and feet 12. Consequently, the aforementioned interconnection points and connection points in each part of the assembly are covered by a polymeric strengthening layer.

Typically, the coating is performed using an injection-molding machine.

In some embodiments, frame support members 12 have a skid proof member underneath for engaging with the floor to inhibit sliding.

Fig. 4 is a flow-chart showing an embodiment of a typical process for producing a pallet of the present invention. At step 42, a plurality of frames 10 are provided; at step 44, inter-connections are formed between one or more frame- support members 12 and each frame 10 of the plurality of frames 10, to form an assembly; at step 46, the assembly is placed into a mold of an injection molding apparatus. At step 48, a polymer is injected into the mold, thereby covering at least the connections between the plurality of frames 10 and the plurality of frame-support members 12. At step 50, the polymer is cured.

It should be noted that some steps of the above described process can be combined, executed repeatedly, rearranged or omitted altogether. While the afore-described embodiments relate to producing an assembly of a plurality, e.g. four frames 10 and a plurality of feet 12, according to some embodiments, the pallet is formed using any number of frames, including fewer than four frames; and may be formed from a single frame.

It should be understood that the above description is merely exemplary and that there are various embodiments of the present invention that may be devised, mutatis mutandis, and that the features described in the above-described embodiments, and those not described herein, may be used separately or in any suitable combination; and the invention can be devised in accordance with embodiments not necessarily described above.