FIELD OF INVENTION

The present invention relates to a modular pallet, and more particularly to an improved modular pallet which is readily configurable into virtually any desired size with ample strength to support different loads.

BACKGROUND OF INVENTION

Pallet is well known for its usage as a loading platform for storage and conveyance of products in quantity. Pallet provides a stable base for a manufacturer or distributor of a product to stack items thereon allowing for ease of movement by use of a forklift or pallet jack. Traditionally, storage pallets have been constructed of wood materials in conventional configurations. Wooden pallets enable to provide years of service if not exposed to severe conditions or unusual loading situations that could cause crumbling or collapse of the wooden frames or components. Although the wooden pallets have adequate strength for years of service, they are relatively heavy which add significantly to the expenses of handling and transportation of goods. Moreover, wooden pallets are in constant need of repair which resulting in an additional expenditure of capital as well as labour.

Another problem with wooden pallets is that insects or other pests can easily burrow into the wood and be transported into and infest uncontaminated storage area. Such insects or pests may continue to reproduce and thrive in the wooden structure of the wooden pallet. Moreover, the exportation of goods on wooden pallets is prohibited in some countries due to concern of introducing pests such as wood beetles. Additionally, wooden pallets allow for absorption of water which adds substantially weight to the pallets, and yet reduces stability and durability. In addition, increase of humidity can also stimulate bacterial or fungal growth in the pallet which may lead to hygiene issues.

Wooden pallets also have a significant disadvantage in that they do not interlace or readily stack. Thus, if a number of wooden pallets are to be placed on top of each other, there is a possibility for the pallets to tip over especially in the event that any of the pallets within the stack slips away from a squarely stacked position above the underlying pallet. Moreover, conventional wooden pallets occupy considerable space.

In the past, woods are relatively inexpensive and simple to work with material. However, as lumber prices have been increased along with the concern of depletion of natural resources, alternative materials have been explored.

An alternative to wooden pallets includes metal pallets, such as those typically formed by aluminum. Metal pallets are known for their durability under normal circumstances. However, aluminum pallets are expensive to manufacture and once damaged, cannot be readily repaired. In the event that any interim damage occurs, such as breach of welded parts, the pallet could have a catastrophic failure under a loaded condition. This could cause injury to operating personnel or damage to the materials positioned on the pallet.

Yet another material used for the construction of pallets is plastic. Plastic is capable of being sterilized, and is resistant to most environmental conditions. However, a plastic pallet is even more difficult to repair than that of metal if it is not modularly constructed. Should a portion of the pallet become damaged, the entire pallet becomes non functional. Many improvements to plastic pallets have been carried out by means of which the pallets are of modularly constructed. However, some of the existing modular formed plastic pallets are found to be unsatisfactory because of their constructions appear to have certain drawbacks such that they have not become widely used. Moreover, some of the existing modular formed plastic pallets are relatively complex in construction, lack strength, and yet difficult in assembly.

In view of these and other shortcomings, it is desirous to provide an improved modular pallet which facilitates readily configurable into virtually any desired size with ample strength to support different loads. The present invention provides an improved modular pallet which is simple in construction, leading both to economy of manufacture and simplicity in assembly. Moreover, the present invention facilitates readily assembling and/or disassembling of component parts without the use of special tools, and yet any damage of component parts is replaceable at competitive costs. In addition, the component parts, fully and/or partially assembled pallets may be conveniently and safely nested or stacked to minimize the storage space.

The improved modular pallet of the present invention and its combination of elements or parts thereof will be described and/or exemplified in the detailed description.

SUMMARY OF THE INVENTION

The present invention relates to an improved modular pallet for supporting loads. The modular pallet includes: a) three spaced apart base members, each having pillars integrally linked by upper girders and lower girders; b) a pair of supporting ribs having a pair of rigid adjoining sections integrally connected by a beam to define a channel; c) a platform having a load-bearing plate with side walls wherein the longitudinal side walls adapted to be matched with the associated parts of the supporting ribs and base members; and d) a plurality of locking members, each having a rigid body integrally extended from a head section.

Each side faces of the pillar of the base member facing toward another adjacent base member is provided with at least one locking slot adapted to facilitate the assembly of the supporting ribs and/or the base member. Preferably, the locking slots of the pillars serve to receive the locking members by means of insertion. It will be appreciated that each locking slot of the pillar is provided with a female interlocking connector. The female interlocking connector can include but is not limited to locking notch. In a preferred embodiment, the side faces of the pillar of the base member facing toward another adjacent base member is also provided with a pair of openings to readily receive corresponding protrusions of the supporting rib.

It should be noted that the base member is provided with recesses, accesses and retainers mutually and collectively operable to receive the platform. The accesses and retainers of the base member are adapted to enable projections at the indented couplers of the platform to be inserted through the accesses, and slidably engaged with the retainers so as enable the platform to be securely slide fitted on the recesses of the base member. The recesses of the base member serve to interlock the platform to the base member by means of stoppers.

The base member is further provided with at least one engagement member at the middle section of the upper girders having accesses and retainers at the upper end to enable the projections at the openings of the platform to be inserted through the accesses, and slidably engaged with the retainers of the engagement member. It will be appreciated that the base member is also provided with reinforcement element, such as lattice frameworks / skeletons adapted to strengthen the structure of the base member.

In accordance with the preferred embodiment of the present invention, the outward face of each rigid adjoining section of the supporting rib is provided with at least one locking slot. It will be appreciated that each locking slot of the rigid adjoining section is provided with a female interlocking connector. The female interlocking connector can include but is not limited to a locking tongue. The outward faces of the adjoining section are also provided with a pair of protrusions and serve to be inserted into their corresponding openings on the pillars of the base member.

The supporting rib is further provided with indented accesses and retaining portions along the longitudinal side walls of the beam collectively operable to receive the platform. The accesses and retaining portions of the supporting rib enable the projections of the platform to be inserted through the accesses, and slidably engaged with the retaining portions.

It will be appreciated that the supporting ribs is adapted to provide sufficient space and strength to enable the forklift equipment or pallet jack to maneuver the pallet by inserting their tines into the channels provided by the supporting ribs.

In a preferred embodiment, the supporting rib comprises a pair of protrusions on the outward face of each rigid adjoining section of the supporting rib, and the pillar of the base member comprises a pair of openings in which the protrusions are to be inserted. If desired, both of the outward face of the supporting rib and the side faces of the pillars facing toward another adjacent base member can also comprise at least one opening in which an independent member is slotted through corresponding openings on the contact faces and coupled both of the supporting rib and base member.

In the preferred embodiment of the present invention, the indented couplers and longitudinal side walls of the platform are provided with projections. It will be appreciated that the projections of the platform are adapted to be placed and comfortably slide fitted with the associated parts of the supporting ribs and base members. The platform is further provided with a plurality of openings along the longitudinal axis passing through the centre of the platform, wherein each opening has a plurality of projections to be slidably fitted with the engagement member of the base member.

The platform is further provided with a plurality of stoppers adapted to serve as retaining means to prevent the platform from being dislodged through interlocking. By way of example but not limitation, the load-bearing plate of the platform is made of solid surface, perforation or meshes. Preferably, the stoppers are integrally protruded from the load-bearing plate of the platform.

In the preferred embodiment, the rigid body of the locking member is made up of two parallel opposed flat side walls, and two inner inclined surfaces defining a mating concave. Further, each side wall of the rigid body is provided with male interlocking connector which is adapted to be slidably snap-fitted into the female interlocking connector at two adjacent locking slots of the base member and supporting rib, respectively. The male interlocking connector can include but is not limited to locking tongue. The mating concave of the locking member serves to further secure the engagement between the base member and the supporting rib by preventing them from being separated.

If desired, the modular pallet of standard-sized may be cut into substantially half for reduction of pallet size. The modular pallet of standard- sized may also be extended to greater area configurations as required. The modular pallets of standard-sized can be securely interlocked in matrix form, such that they are distributed in multiple rows and columns for increment of pallet size

The present invention consists of several novel features and a combination of parts hereinafter fully described and illustrated in the accompanying description and drawings, it being understood that various changes in the details may be made without departing from the scope of the invention or sacrificing any of the advantages of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, wherein:

Fig. 1 is an exploded perspective view of a modular pallet in accordance with preferred embodiment of the present invention;

Fig. 2a is an assembled perspective view of the modular pallet of standard-sized in accordance with the preferred embodiment of the present invention; Fig. 2b illustrates a plan view, front view and side view of the modular pallet of Fig. 2a;

Fig. 2c illustrates a bottom view of the modular pallet of Fig. 2a;

Fig. 3a is a perspective view of a platform of the modular pallet in accordance with preferred embodiment of the present invention;

Fig. 3b illustrates a plan view, front view and side view of the modular platform of Fig. 3a;

Fig. 3c is an enlarged side view of the modular platform at each circular portion of Fig. 3b;

Fig. 4a is a perspective view of a base member of the modular pallet in accordance with the preferred embodiment of the present invention;

Fig. 4b shows a plan view, front view, side view and bottom view of the base member of Fig. 4a;

Fig. 5a a perspective view of a supporting rib of the modular pallet in accordance with preferred embodiment of the present invention;

Fig. 5b shows a plan view, front view and side view of the supporting rib of Fig. 5a;

Fig. 6a is a perspective view of a locking member of the modular pallet in accordance with preferred embodiment of the present invention;

Fig. 6b shows a plan view, front view, side view and bottom view of the locking member of Fig. 6a;

Fig. 7 illustrates a modular pallet of standard-sized enables to be cut into substantially half for reduction of pallet size;

Fig. 8 illustrates a plurality of modular pallets is being interlocked for increment of pallet size. Detailed Description of the Preferred Embodiments

The present invention relates to an improved modular pallet for supporting loads. Hereinafter, this specification will describe the present invention according to the preferred embodiments. However, it is to be understood that limiting the description to the preferred embodiments of the invention is merely to facilitate discussion of the present invention and it is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the scope of the appended claims.

The present invention aims to provide a solution to reduce if not eliminate the aforesaid problems by providing an improved modular pallet having component parts to allow unique modular construction. The present invention provides an improved modular pallet which is readily configurable into virtually any desired size with ample strength to support different loads.

Accordingly, the present invention provides an improved modular pallet which is simple in construction, leading both to economy of manufacture and simplicity in assembly. Moreover, the present invention facilitates readily assembling and/or disassembling of component parts without the use of special tools, and yet any damage of component parts may be easily replaceable at competitive costs.

It should be noted that each component part of the modular pallet of the present invention is intended to meet its own features so as to provide a robust structure. Preferably, each component part of the modular pallet uses materials that can be recycled without compromising the performance of the pallet, which may well be part of a sustainable development approach. It should also be noted that the component parts, the fully and/or partially assembled pallets may be conveniently and safely nested or stacked to minimize the storage space. Additionally, the component parts may also be easily assembled to form storage pallets of varying sizes. Although the component parts of a given pallet are securely interlocked, they can be conveniently separated if desired. The component parts are thin walled and hence lightweight and inexpensive, yet provide sufficient strength.

The improved modular pallet for supporting loads according to the preferred mode of carrying out the present invention will now be described in accordance to the accompanying drawings Figs. 1 to 8, either individually or in any combination thereof.

Referring to Figs. 1 to 2c, illustrated therein is an assembly of the improved modular pallet 10 according to preferred embodiment of the present invention. The improved modular pallet 10 generally comprised of modular component parts which are interlockably assembled to form a standard-sized rigid structure / framework for supporting loads. The modular component parts generally include base members 20, supporting ribs 30, platforms 40, and locking members 50. The modular pallet 10 of standard-sized is generally formed by at least three units of base members 20, at least three pairs of supporting ribs 30, at least one pair of platforms 40 and a plurality of locking members 50. It should be noted that the modular pallet 10 includes a unique arrangement of the modular component parts which having novel features to provide a rigid structure as well as to increase load carrying capacity.

By way of example but not by way of limitation, the modular component parts of the modular pallet 10 may be formed from plastic, polymer or composite materials, so that they are impervious to water and/or pestilent creatures and bacteria. It will be appreciated that the plastic, polymer or composite formed materials also provide lightweight component parts and yet relatively strong in structure.

Referring now to Figs. 3a to 3c, the platform 40 of the modular pallet 10 generally includes a load-bearing plate 40a with side walls 48a and 48b. The load-bearing plate 40a can be in the form of solid surface, perforation or meshes 40b. By way of example but not limitation, the perforations or meshes 40b may be in the form of honeycomb, square, rectangular or any other shapes deemed suitable to strengthen or reinforce the structure of the platform 40. It will be appreciated that the platform 40 is suitably provided with a plurality of indented couplers 44 and a plurality of projections 42a and 42b at the indented couplers 44 and the longitudinal side walls 48 to allow the platform 40 to be interlockably engaged with the associated parts of the supporting ribs 30 and base members 20. During assembly of the embodiments of the unique modular pallet of the present invention, the projections 48a at the indented couplers 44 of the platform are inserted through at least one indented access 28a at the upper end of the pillars 22a, 22b, 22c at the faces linked by the upper girdles 25 of the base member and slidably engaged with the retainer 28b at the upper end of the pillars 22a, 22b, 22c.

In accordance with the preferred embodiment of the present invention, the platform 40 may be slidably fitted with partially assembled pallet, i.e. with the base member 20 and the supporting rib 30 being arranged and in partially assembled form, by either from middle or edges of the arranged and/or partially assembled form of the pallet during the assembly. In the preferred embodiment, the platform 40 is further provided with a plurality of openings 46 positioned along the longitudinal axis passing through the centre of the platform 40 wherein each opening 46 has a plurality of projections 42c on the side walls of the opening 46 parallel to the longitudinal side walls 48a of the platform 40. The projections 42c of the opening 46 of the platform 40 are inserted through the indented access 28a and slidably engaged with the retainers on the engagement member 23 of the base member 20 to further secure the engagement between the platform 40 and the base member 20.

The platform 40 of the modular pallet 10 is further provided with a plurality of stoppers 49 suitably positioned at the bottom surface of the platform 40. Preferably, the stoppers 49 are integrally protruded from the load-bearing plate 40a of the platform 40. It will be appreciated that the stoppers 49 are adapted to serve as retaining means to interlockably engage the platform 40 to the base member 20. In particular, the stoppers 49 are adapted to be slidably engaged with the recesses 25a at the upper girders 25 of the base member 20 to prevent the platform 40 from being dislodged.

Referring to Figs. 4a and 4b, the base member 20 generally includes pillars 22a, 22b, and 22c, upper girders 25 and lower girders 27. Accordingly, the pillars 22a, 22b, 22c are integrally linked by the upper girders 25 and lower girders 27. The side faces of the pillars 22a, 22b, 22c of the base member 20 facing toward another adjacent base member 20 is provided with locking slots 26 adapted to facilitate the assembly of the supporting ribs 30 and/or the base member 20 depending upon the configuration and usage of the pallet. In a preferred embodiment, the locking slot 26a of the base member 20 is mutually aligned with the locking slot 26a of the supporting rib 30 to form a receiving hole that could readily receive the locking members 50 by means of insertion. It should be noted that each locking slot 26 of the pillar 22a, 22b, 22c of base member 20 is provided with a female interlocking connector. The female interlocking connector can include but is not limited to locking notch 26a.

In the preferred embodiment, the base member 20 is provided with recesses 25a, accesses 28a and retainers 28b which are mutually and collectively operable to receive the platform 40. The accesses 28a and retainers 28b are positioned at the upper ends of the pillars 22a, 22b, 22c of the base member 20. The accesses 28a and retainers 28b at the pillars 22a, 22b, 22c of the base member 20 are adapted to enable the projections 42a at the indented couplers 44 of the platform 40 to be inserted through the accesses 28a and slidably engaged with the retainers 28b of the base member 20. The recesses 25a positioned at longitudinal edge of the upper girder 25 of the base member 20 are served to be interlockaby engaged by the stoppers 49 of the platform 40 to prevent the platform 40 from being dislodged once engaged to the base member 20.

In accordance with the preferred embodiment of the present invention, each side faces of the pillars 22a, 22b, 22c of the base member 20 facing toward another adjacent base member 20 is provided with a pair of openings 24 to readily receive the corresponding protrusions 32a of the supporting rib 30.

The base member 20 is further provided with at least one engagement member 23 at the middle section of the upper girders 25 having indented accesses 25a and retainers 25b at the upper end of the engagement member 23 positioned to correspond to the indented accesses 28a and retainers 28b at the pillars 22a, 22b, 22c of the base member 20 to enable the projections 42c at the openings of the platform 40 to be inserted through the indented accesses 25a, and slidably engaged with the retainers 25b of the engagement member 23.

The base member 20 is further provided with reinforcement element. The reinforcement element may be lattice frameworks / skeletons 29 that are adapted to strengthen the structure of the base member 20. By way of example but not limitation, the lattice frameworks / skeletons 29 may be in the form of square, rectangular or any other shapes deemed suitable for the same purpose.

Referring to Figs. 5a and 5b, the supporting rib 30 generally includes a beam 34 having side walls 37a and 37b. The supporting rib 30 also includes a pair of rigid adjoining sections 32, one at each transverse side walls 37b of the beam 34 integrally connected by the beam 34 to define a channel 35 for forklift's or pallet jeck's tine insertion.

In accordance with the preferred embodiment of the present invention, the outward faces of the rigid adjoining section 32 are provided with a pair of protrusions 32a adapted to be matingly engaged with the corresponding openings 24 of the pillars 22a, 22b, 22c of the base member 20. If desired, both of the outward face of the supporting rib 30 and the side faces of the pillars 22a, 22b, 22c facing toward another adjacent base member 20 can also include at least one opening in which an independent member is slotted through corresponding openings on the contact faces and coupled both of the supporting rib 30 and base member 20. The independent member must have the same cross-sectional shape and slightly less cross-sectional area as the corresponding opening into which it will be slotted. It will be appreciated that the outward faces of the rigid adjoining section 32 also provided with a locking slot 26 adapted to receive the locking members 50. In a preferred embodiment, the locking slot 26a of the supporting rib 30 is mutually aligned with the locking slot 26a of the base member 20 to form a receiving hole serves to readily receive the locking members 50 by means of insertion. Each locking slot 26 of the supporting rib 30 is provided with a female interlocking connector. The female interlocking connector can include but is not limited to locking notch 26a.

The supporting rib 30 is further provided with indented accesses 36a and retaining portions 36b positioned along the longitudinal side walls 37a of the beam 34. Accordingly, the indented accesses 36a and retaining portions 36b are collectively operable to receive the platform 40. The indented accesses 36a and retaining portions 36b of the supporting rib 30 enable the projections 42b at the longitudinal side walls 48a of the platform 40 to be inserted through the indented accesses 36a and slidably engaged with the retaining portions 36b of the supporting rib 30.

In the preferred embodiment, each supporting rib 30 is adapted to serve as strengthening / securing means for the modular pallet 10. Accordingly, the supporting ribs 30 secure and/or strengthen the entire structure of the pallet by cross -linking / -interlocking with the base members 20 and platforms 40, to prevent any deformation or distortion of the structure of the pallet. It should be note that the cross -linking / -interlocking between the supporting ribs 30 and platforms 40 prevents the platforms 40 from being dislodged.

It will be appreciated that the supporting ribs 30 of the modular pallet 10 is adapted to provide sufficient space and strength to enable the forklift equipment or pallet jack to maneuver the pallet by inserting their tines into the channels 35 provided by the supporting ribs 30.

Figs. 6a and 6b show the locking member 50 of the modular pallet 10 according to the preferred embodiment of the present invention. By way of example but not limitation, the locking member 50 includes a rigid body 52 integrally extended from a head section 54. The rigid body 52 is made up of two parallel opposed flat side walls 52a, and two inner inclined surfaces 52b defining a mating concave 56. If desired, the rigid body 52 can be made up of four flat side walls. It will be appreciated that the mating concave 56 of the locking member 50 facilitates to further secure the engagement between the base member 20 and the supporting rib 30 to prevent the base member 20 and supporting rib 30 from being readily separated once interlockably assembled.

In accordance with the preferred embodiment of the present invention, each side wall 52a is provided with a male interlocking connector adapted to be slidably snap-fitted into the female interlocking connectors of two adjacent locking slots 26 of the base member 20 and supporting rib 30, respectively. The male interlocking connector can include but is not limited to retaining tongue 58.

The modular pallet 10 of standard-sized is particularly convenient in materials handling because forklift equipment or pallet jack can maneuver the pallet by inserting their forklift tines into the channels provided by the pallet.

However, if desired, the modular pallet 10 of standard-sized may be cut into substantially half for reduction of size as illutrated in Fig. 7.

It will be appreciated that the modular pallet 10 of standard-sized may also be extended to greater area configurations as required. Accordingly, a plurality of modular pallets 10 of standardad-sized may be securely interlocked in matrix form, such that they are distributed in multiple rows and columns for increasing the size of the pallet as shown in Fig. 8. Additional locking members 50 may be utilized for such interlocking.

It should be noted that the configurations of various component parts and elements used to carry out the above-mentioned embodiments are illustrative and exemplary only. One of ordinary skill in the art would recognize that those configurations, component parts and elements used herein may be altered in a manner so as to obtain different effects or desired operating characteristics. As such, the above-described should not be construed as limiting in any way, but as a best-contemplated mode of carrying out the invention.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the principle and scope of the invention, and all such modifications as would obvious to one skilled in the art intended to be included within the scope of following claims.