Pallets for Holding Panels

FIELD OF THE INVENTION

The invention relates to pallets for holding panels. In particular, the invention relates to pallets that can be stacked together to allow for the holding of multiple panels, and in particular, solar panels.

BACKGROUND OF THE INVENTION Solar panels are typically large, thin, rectangular units made from a semiconductor film and a glass covering. Because of this, solar panels are typically fragile and must be stored and transported with care. Presently, when a number of solar panels is being transported, they are often transported in steel cages or in custom- designed packaging assemblies. These packaging assemblies typically comprise a wooden pallet, a corrugated box, and and corrugated cardboard inserts to separate the solar panels from one another. Steel cages are expensive to manufacture and typically require a chrome finish to prevent rusting. The packaging assemblies described above, while cheaper to manufacture than steel cages, are single-use only. This results in higher costs, as the packaging assemblies must be replaced often. They are also not environmentally- friendly as the cardboard materials must be disposed of after they have been used.

Therefore, there is a need for a cost-effective, practical, and environmentally- friendly, re-usable alternative to holding and transporting panels. SUMMARY OF THE INVENTION

A pallet for holding one or more panels comprises a body, one or more dividers attached to the body, and a base. The body comprises two substantially parallel first sides and two substantially parallel second sides, wherein the first sides are substantially perpendicular to the second sides and the first sides and the second sides form a substantially rectangular frame. The body further comprises a plurality of columns extending perpendicularly from the substantially rectangular frame, wherein each of the columns comprises either a male connector or a female connector at a top of the columns. The body further comprises a plurality of feet, wherein the feet extend substantially perpendicularly from the substantially rectangular frame in an opposite direction to the columns. The dividers comprise a plurality of grooves, wherein at least one of the grooves is of sufficient width to allow the insertion of an edge of one of the panels. The base is attached to the feet.

In another embodiment, the plurality of columns comprises four columns, wherein one of said four columns extends from each corner of said substantially rectangular frame. In yet another embodiment, the male connector comprises a knob and a ledge formed below said knob, the ledge extending away from a perimeter of said knob. The female connector comprises a lip, the lip adapted to fit over the knob of another pallet and to rest against the ledge of the other pallet. In another embodiment, the dividers are integrally formed with the rectangular frame. In a further embodiment, the grooves alternate between shallow grooves and deep grooves.

In yet a further embodiment, each of the dividers comprises a molding and an insert. The molding comprises the shallow grooves and the deep grooves, wherein each of the shallow grooves and each of the deep grooves comprises an open bottom. The insert comprises a series of peaks alternating with a series of troughs. The molding fits over the insert and each of the peaks protrude through the bottoms of each of the shallow grooves and each of the troughs protrude through the bottoms of each of the deep grooves.

In another embodiment, the insert comprises a cushioning material, such as foam.

A pallet for holding solar panels comprises a body, one or more dividers attached to the body, and a base. The body comprises a rectangular frame; one or more brace members spanning two sides of the rectangular frame; four columns extending perpendicularly from the rectangular frame, wherein each of the columns comprises either a male connector or a female connector at a top of the columns; and at least one feet at each corner of the rectangular frame. Each of the feet extends perpendicularly from the rectangular frame in an opposite direction to the columns. The feet are hollow and open on at least one end. The dividers are attached to the body, and the dividers comprise an alternating series of shallow grooves and deep grooves, wherein each of the shallow grooves and deep grooves is of sufficient width to allow the insertion of an edge of one of the solar panels. The base comprises sockets for attachment to the feet.

A method for storing one or more panels comprises providing a first pallet and providing a second pallet. The first pallet comprises a first rectangular frame, four first columns extending from the first rectangular frame, wherein each of the first columns comprises either a male connector or a female connector, and one or more first dividers, wherein each of the first dividers comprises first grooves. The second pallet comprises a second rectangular frame, four second columns extending from the second rectangular frame, wherein each of the second columns comprises either the male connector or the female connector. The method further comprises placing one or more of the panels into the first pallet such that an edge of each of the panels is inserted into one of the first grooves and attaching the second pallet onto the first pallet by fitting the male connectors of the second pallet onto the female connectors of the first pallet and by fitting the female connectors of the second pallet onto the male connectors of the first pallet. The method further comprises inserting an opposing edge of each of the panels into one of the second grooves.

The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described by reference to the detailed description of the preferred embodiment and to the drawings thereof in which:

Fig. 1 is a top perspective view of the preferred embodiment of the pallet according to the invention;

Fig. 2 is a bottom perspective view of the pallet;

Fig. 3 is a top view of the pallet;

Fig. 4 is a side view of the pallet;

Fig. 5 is a front view of the pallet;

Fig. 6 is a bottom view of the pallet;

Fig. 7 is a top perspective view of the body of the preferred embodiment of the pallet;

Fig. 8 is a bottom perspective view of the body of the pallet;

Fig. 9 is a top view of the body of the pallet;

Fig. 10 is a side view of the body of the pallet;

Fig. 11 is a front view of the body of the pallet; Fig. 12 is a bottom view of the body of the pallet;

Fig. 13 shows two pallets attached together with panels held within the pallets; Fig. 14 shows two pallets attached together without panels held within the pallets;

Fig. 15 shows a side view of two pallets attached together;

Fig. 16 is a cross-sectional view of Fig. 15, taken along line D-D;

Fig. 17 is a cross-sectional view of Fig. 15, taken along line G-G;

Fig. 18 shows a side view of two pallets attached together, with panels held within the pallets;

Fig. 19 is a cross-sectional view of Fig. 18, taken along line A-A;

Fig. 20 is a magnified view of the encircled portion of Fig. 19;

Fig. 21 is a perspective view of a divider;

Fig. 22 is an exploded view of the divider of Fig. 21 ;

Fig. 23 is another exploded view of the divider of Fig. 21 ;

Fig. 24 is a top view of the divider;

Fig. 25 is a side view of the divider;

Fig. 26 is a front view of the divider;

Fig. 27 is a perspective view showing three pallets nested together;

Fig. 28 is a side view showing three pallets nested together;

Fig. 29 is a cross-sectional view of Fig. 28, taken along line C-C;

Fig. 30 is another side view showing three pallets nested together;

Fig. 31 is a cross-sectional view of Fig. 30, taken along line E-E;

Fig. 32 is a magnified view of the encircled portion of Fig. 31 ;

Fig. 33 is a bottom perspective view showing three pallets, with two pallets fully nested and one pallet partially nested;

Fig. 34 is a magnified view of the encircled portion of Fig. 33;

Fig. 35 is a cross-sectional perspective view showing three pallets, with two pallets fully nested and one pallet partially nested;

Fig. 36 is a magnified view of the encircled portion of Fig. 35;

Fig. 37 is an exploded view showing two pallets, with panels held within the pallets; Fig. 38 shows an alternate embodiment of the pallet; and

Fig. 39 shows an alternate embodiment of the divider.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to Figs. 1 to 6, the pallet 10 of the present invention comprises a body 12 and a base 14. The body 12 comprises two substantially parallel first sides 16 and two substantially parallel second sides 18, with the first sides 16 being perpendicular to the second sides 18, forming a substantially rectangular frame 20. One or more brace members 22 may span the first sides 16 or the second sides 18 to increase the overall rigidity of the rectangular frame 20. A plurality of columns 24, 25, 26, 27 protrude above the rectangular frame 20, preferably at the corners. Preferably, the columns 24, 25, 26, 27 are integrally formed with the body 12 and may be made from an unitary mold; however, it is also possible for the columns 24, 25, 26, 27 to be constructed separately from the rest of the body 12 and subsequently attached to the rectangular frame 20. The columns 24, 25, 26, 27 may extend substantially perpendicularly to both the first sides 16 and the second sides 18.

Referring to Figs. 7 to 12, in the preferred embodiment, the body 12 further comprises one or more feet 28 that extend below the first sides 16 and the second sides 18. The feet 28 are preferably located at the corners of the rectangular frame 20, although additional feet 28 may also be present to give additional support to the body 12. These additional feet 28 may be found at various points below the first sides 16, the second sides 18, or the brace members 22. The feet 28 provide a degree of structural strength and rigidity to the body 12. The base 14 fits under the body 12 and contains sockets 30 that correspond with the feet 28. The base 14 may also comprise straps 32 that span the sockets 30.

The feet 28 raise the height of the body 12 and allow for the pallet 10 to be easily used with machinery such as forklifts and pallet jacks. The straps 32 connect the sockets 30. This separation may be used as a handle or as a means for machinery to manipulate the pallet 10. The straps 32 also allow for the pallet 10 to be more easily flipped over or for assembly/disassembly (either manually or automatically).

The pallet 10 further comprises one or more dividers 34. The dividers 34 preferably span between the second sides 18 and lie on the rectangular frame 20. Each of the dividers 34 comprises a series of grooves 36 that run parallel to the second sides 18. Each of the grooves 36 is of sufficient width to accommodate the thickness of one of the panels 5 being held in the pallet 10. Preferably, the dividers 34 are not integral with the body 12 but are instead formed separately. However, even though the dividers 34 are not integral with the body 12, they may be attached to the body 12. Any appropriate attachment mechanism may be used, including but not limited to using an adhesive, riveting, physically fitting them together using a slot and tab fit, or using other mechanical connectors. Figs. 21 to 26 show details of the dividers 34. Each of the dividers 34 comprises a top molding 40 and a bottom insert 42 that fit together to form the divider 34. Referring to Figs. 22 and 23, which show exploded views of one of the dividers 34, the molding 40 comprises a series of deep grooves 39 that alternate with a series of shallow grooves 38. The bottom of each of the deep grooves 39 and the shallow grooves 38 is open. Preferably, the molding 40 is made of plastic.

The insert 42 is preferably made of foam or other suitable cushioning material (e.g. an elastomeric plastic) and comprises a series of peaks 44 that alternate with a series of troughs 45. The distance between the top of the peaks 44 and the bottom of the insert 42 is greater than the distance between the bottom of the shallow grooves 38 and the bottom of the molding 40. The distance between the top of the troughs 45 and the bottom of the insert 42 is greater than the distance between the bottom of the deep grooves 39 and the bottom of the molding 40. Because the bottoms of the shallow grooves 38 are open, when the insert 42 is fitted into the molding 40, the peaks 44 will protrude through the bottoms of the shallow grooves 160. Similarly, the troughs 45 will protrude through the bottoms of the deep grooves 39. This results in a divider 34 with an alternating series of deep grooves 39 and shallow grooves 38, with the bottom of each of the deep grooves 39 and the shallow grooves 38 having a foam cushioning base. When the edges of the panels 5 to be stored are inserted into the deep grooves 39 and the shallow grooves 38, the edges of the panels 5 contact the foam of the insert 42, providing a cushioning effect for the panels 5.

After the insert 42 is fitted into the molding 40 to form the divider 34, the divider 34 is preferably attached to the body 12 through the molding 40. Preferably, the molding 40 of the divider 34 is made from plastic, which makes its attachment to the body 12 easier than if attachment was made through the insert 42, which is preferably made of foam.

Preferably, the columns 24, 25, 26, 27 are tapered and rounded. The free, top end of each of the columns 24, 25, 26, 27 comprises either a male connector 46 or a female connector 48. In the embodiment shown in Figs. 1 to 6, columns 25, 27 comprise a male connector 46 while columns 24, 26 comprise a female connector 48, although other combinations are also possible. The male connector 46 comprises a ledge 50 formed below a knob 52 on the ends of the columns 25, 27. Where the columns 25, 27 are round (as in the preferred embodiment), the knob 52 may have a substantially circular cross-section, and the ledge 50 will extend away from the circumference of the knob 52. The female connector 48 comprises a lip 54 on the tops of the columns 24, 26, creating a hollow opening 56 at the ends of the columns 24, 26. The lip 54 may be a single wall or a double wall. The male connector 46 and the female connector 48 are so shaped as to allow the lip 54 of the female connector 48 to fit over the knob 52 of the male connector 46 and to rest against the ledge 50, as shown in Figs. 13 to 20 and especially Fig. 16. In the preferred embodiment, two of the columns 24, 25, 26, 27 have a male connector 46 and the other two of the columns 24, 25, 26, 27 have a female connector 48. Referring to Figs. 13 to 20, when the columns 24, 25, 26, 27 of the pallet 10 are attached to the corresponding columns 24, 25, 26, 27 of a similar second pallet 10 (i.e. the male connectors 46 of one pallet 10 is connected to the female connectors 48 of the second pallet 10), the two pallets 10 form an enclosure, or cage 60. Through the interaction of the male connectors 46 and the female connectors 48 of the respective columns 24, 25, 26, 27 of the two pallets 10, the two pallets 10 are held securely together. The columns 24, 25, 26, 27 of the two respective pallets 10 are of sufficient length so that when the two pallets 10 are connected together to form the cage 60, one or more panels 5 will fit securely within the cage 60 and will be held within the grooves 36 of the pallets 10, as shown in Figs. 18 to 20. Referring specifically to Fig. 20, each of the grooves 36 on the bottom pallet 10 will have a corresponding groove 36 directly above it on the top pallet 10. Because each of the dividers 34 have an alternating series of deep grooves 39 and shallow grooves 38, when the two pallets 10 are attached together to form the cage 60, a deep groove 39 on the bottom pallet 10 will correspond to a shallow groove 38 on the top pallet 10. Similarly, a shallow groove 38 on the bottom pallet 10 will correspond to a deep groove 39 on the top pallet 10. This ensures that all of the grooves 36 of the bottom and top pallets 10 will fit similarly sized panels 5.

In the preferred embodiment, when the panels 5 are stored in the cage 60, the panels 5 will be arranged parallel to one another and will be arranged substantially perpendicularly to the rectangular frames 20 of the top and bottom pallets 10. However, because of the arrangement of the grooves 36, the panels 5 will be staggered.

The interior of each of the columns 24, 25, 26, 27 is substantially hollow, especially in their lower portions. It is possible that there may be internal ribbing or gusseting for the upper portions of the columns 24, 25, 26, 27 in order to increase the strength of the columns 24, 25, 26, 27. Furthermore, in the preferred embodiment, each of the columns 24, 25, 26, 27 not only protrudes above the body 12 but also extends through the body 12, as shown in Figs. 7 to 12. The bottoms of each of the columns 24, 25, 26, 27 passing through the body 12 may be conterminous with part of one of the feet 28. Preferably, the feet 28 are hollow. The sockets 30 preferably fit within the feet 28 and comprise one or more openings. The bottom portions of each of the columns 24, 25, 26, 27 forms a channel 58 that runs through a foot 28 and a socket 30. These channels 58 are open on the base 14. Because of the tapered shaped of the columns 24, 25, 26, 27, it is also possible to nest the pallet 10 on top of another similar pallet 10 (as shown in Figs. 27 to 36), with the columns 24, 25, 26, 27 of the pallet 10 nesting over the columns 24, 25, 26,

27 of the pallet 10 below it. This is possible because of the columns 24, 25, 26, 27 of the bottom pallet 10 can be placed into the channels 58 of the top pallet 10. Multiple pallets 10 may be nested on top of each other to reduce the storage space required to transport or store the pallets 10 when they are not used to hold panels 5.

When pallets 10 are nested on top of each other as described above, since the dividers 34 protrude from the top of the rectangular frame 20, it is possible that the dividers 34 of the bottom pallet 10 will interfere or abut into the underside of the pallet 10 that is stacked on top of it and prevent optimal nesting of the columns 24, 25, 26, 27. In order to prevent such interference, the feet 28 located at the corners of the body 12 may be elongated and hollowed out from below, as shown in Fig. 8. Furthermore, the sockets 30, which preferably fit within the feet 28, comprise divider openings 59. By elongating and hollowing the feet 28 and by having divider openings 59, when the top pallet 10 is stacked on top of the bottom pallet 10 (as shown in Figs. 30 to 36), the lateral portions of the dividers 34 of the bottom pallet 10 will slide through the divider openings 59 and fit within the space formed by the hollowed feet

28 of the top pallet 10. The interior walls of the feet 28 and sockets 30 of the top pallet 10 will slide within the grooves 36 of the bottom pallet 10 and allow for increased nesting of the columns 24, 25, 26, 27.

In an alternate embodiment of the invention, as shown in Fig. 38, the dividers 34 may be integrally formed with the body 12. In this embodiment, the dividers 34 also comprise alternating deep grooves 39 and shallow grooves 38; however, instead of having a separate insert, a small amount of foam or other suitable cushioning material is attached to the troughs of each of the deep grooves 39 and shallow grooves 38.

In another embodiment of the invention (shown in Fig. 39), the dividers 34 are made entirely from a cushioning material, such as foam or elastomeric plastic. In this embodiment, the dividers 34 may be made separately from the body 12 and later attached to the body 12. The dividers 34 still comprise a series of alternating deep grooves 39 and shallow grooves 38. Although the present invention may be used with any type of panels, it is particularly suited for solar panels, because of the fragility and size of solar panels.

It is not necessary for all of the grooves 36 to be occupied by the panels 5. In addition, the panels 5 may be strapped together to further secure them within the cage 60.

The present invention provides a degree of protection to the panels 5 during transport. The cushioning material, such as foam, in the dividers 34, protects the edges of the panels 5. Furthermore, the robust and rigid geometry of the two pallets 10 forming the cage 60 means that the panels 5 are not placed under any load other than their own weight while in transit.

The present invention also holds the panels 5 in a defined upright geometry and prevents them from falling into each other by keeping a particular spacing between each of the panels 5.

In the preferred embodiment, the pallet 10 is constructed of recycled or virgin polyethylene plastic and is made by low-pressure injection molding, which injects inert gas and plastic into a mold. The use of low-pressure injection molding allows for the construction of such a relatively large-sized pallet. Low-pressure injection molded polyethylene results in a matte, softer, more adherent surface. This is less harsh on the surface of the solar panels. Where a smaller-sized pallet is required, high-pressure injection molding may be used instead. The pallet 10 can be reused multiple times, unlike the convention cardboard boxes currently in use. This is of economic and environmental benefit.

In the preferred embodiment, the dividers 34 comprise a sufficient number of grooves 36 to accommodate up to fifty panels 5. However, alternatively, shorter dividers may also be used, enabling the use of two or more strapped bundles of panels 5 in one cage 60. This may also allow the handling of smaller quantities of panels 5.

The invention as described above offers a space-efficient solution for storing solar panels. It is a storage solution that allows for the panels to be secure at their top and bottom edges. It is an efficient way to transport panels close to each while still maintaining a physical separation in between the panels.

The use of a molded pallet, as in the present invention, has more replicable geometry than the use of a packaging assembly. This will aid automation by the user.

The present invention, through the use of relatively large-diameter columns 24, 25, 26, 27, provides a large load-carrying capacity. In particular, the present invention allows for the stacking of multiple pallets 10 (and in turn multiple cages 60) on top of each other. For example, the stacking of three or more cages 60 on top of each other may be possible. Current conventional packaging assemblies do not allow for such stacking.

It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.