FIELD OF THE INVENTION

This invention relates to pallets for the transport and storage of goods.

BACKGROUND TO THE INVENTION

Pallets are made in various sizes and with various designs, depending on the purpose for which they are intended to be used. In particular, pallets need to have standard sizes to be used on standardised handling systems, warehousing systems, transport means (such as containers), etc. , but there are various standard sizes of pallets used in different applications. Depending on the ways in which pallets are to be handled, there can also be various other requirements, e.g. if various pallets are stacked (un-laden), it may be necessary to remove a single pallet easily - this is particularly important where pallets are nested in a stack and individual pallets need to be lifted from the stack by automated lifting equipment. If laden pallets are to be double-stacked, the undersides of the pallets need to be of a configuration that would allow it to rest on top of the load of the pallet below. Another example of geometric requirements is that the apertures where tines of a lifting fork need to enter, vary depending on whether the tines are of a fork-lift, a lift jack, or automated lifting equipment.

Pallets also need to have an appropriate durability load carrying capacity, for static loads, dynamic loads, racking, stacking, etc., yet be cost effective. Further, apart from these various attributes of pallets, the design of a pallet can be determined by the method in which it is intended to be used - e.g. if pallets need to be transported (laden or empty), they should occupy the least space. Pallets should also weigh as little as possible, to save costs in various ways, mostly in manufacturing and transport costs, but also because the cost of every lifting operation or elevated storage operation increases with weight. The present invention seeks to provide pallets that are cost-effective, yet are versatile and can be used for various applications. The attributes that provide the versatility of the pallets include, but are not limited to: the ability to nest, rack, stack (laden and un- laden), carry heavy loads (static and dynamic), to be convertible between different sizes and configurations of pallets, and to increase usable load space.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided a pallet comprising a generally planar load deck and a plurality of feet extending on one side of the load deck, each of said feet having attachment formations that are releasably attachable to complementary attachment formations on the feet of another such pallet, so that the load decks of the pallets are generally parallel when the attachment formations of the feet of the pallets are attached, each foot defining support formations on its underside, so that each pallet can bear a load, while supported on its feet.

At least some of the attachment formations may be recessed from the undersides of the support formations.

The feet may be hollow and may have walls that taper, such that the pallets can be stacked - with feet of one pallet extending partly into the inside cavities of the feet of the pallet immediately below in the stack. The feet may have island formations, disposed inside the cavities of the feet, each island being hollow, with a tapering wall and defining a load surface that is generally aligned with the load deck.

The invention extends to a plurality of said pallets, the spacing of the attachment formations on the pallets' feet being similar between the pallets, but the sizes of the pallets' decks being similar or begin different.

According to another aspect of the present invention there is provided a method of transforming a first pallet, said first pallet being substantially as described above, and said method comprising inverting a second pallet, being a pallet as described above and attaching the attachment formations on the feet of the first and second pallet together. The method may include removing the second pallet from the first pallet by releasing the attachment between the first and second pallets' attachment formations and the releasable attachment may include applying a separating force between the first and second pallets, which may be about 300N.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show how it may be carried into effect, the invention will now be described by way of non-limiting example, with reference to the accompanying drawings in which:

Figure 1 shows a top perspective view of a first embodiment of a pallet according to the present invention;

Figure 2 shows a detail top perspective view of a foot of the pallet of Figure 1 ;

Figure 3 shows a bottom perspective view of the pallet of Figure 1 ;

Figure 4 shows a detail bottom perspective view of a foot of the pallet of Figure 1 ; Figure 5 shows a side view of the pallet of Figure 1 ;

Figure 6 shows a side perspective view of two of the pallets of Figure 1 , attached together according to the present invention;

Figure 7 shows a top perspective view of the attached pallets of Figure 6;

Figure 8 shows a detail top perspective view of attached feet of the attached pallets of Figure 6;

Figure 9 is a side view of the pallet of Figure 1 , attached to a similar pallet with a different deck size;

Figure 10 shows a top perspective view of a second embodiment of a pallet according to the present invention;

Figure 1 1 shows a bottom perspective view of the pallet of Figure 10;

Figure 12 shows a top perspective view of five of the pallets of Figure 10, stacked in a nesting manner; and

Figure 13 shows a top perspective view of two of the pallets of Figure 10, attached together according to the present invention. DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings, a pallet according to the present invention is generally indicated by reference numeral 10, but the first embodiment of the pallet, as shown in Figures 1 to 9, is indentified by a suffix 1 , and the second embodiment of the pallet, as shown in Figures 10 to 13, is identified by suffix 2. Parts of the pallets that are similar between the two embodiments, are identified by like reference numerals.

Referring to Figures 1 to 9, the pallet 10.1 comprises a generally planar load deck 12.1 and nine feet 14.1 , although the number of feet and the positions of the feet can be different, depending on the load carrying ability of the pallet 10.1 that is required. In particular, if the pallet 10.1 is required to be double-stacked on top of laden pallets, or to carry heavy loads, the number of feet 14.1 could be higher. The spacing between the feet 14.1 is such that it can allow easy access for the tines of a lifting device between them.

As best seen in Figures 2 and 4, the deck 12.1 has a lattice structure, defining a plurality of cavities 16.1 with webs 18.1 between them and with apertures 19.1 in some of the webs - giving the deck a light-weight, strong construction. As best seen in Figure 1 , nine square apertures 20.1 are defined through the deck 12.1 - one above each foot 14.1 .

As best seen in Figure 2, each of the feet 14.1 as a generally square profile from above and is hollow, with an internal cavity 26.6 that is continuous with the aperture 20.1 in the deck 12.1 , immediately above the foot. The walls 28.1 of each foot 14.1 taper and each foot has a number of apertures 32.1 in its walls, to reduce its weight. Inside the cavity 26.1 of each of the feet 14.1 , there is an island formation 36.1 that is hollow, with tapering walls 38.1 that extend upwards from the underside of the foot, to the top of the island formation, where it includes a load surface 40.1 that is generally aligned with the top of the deck 12.1 . The island formations 36.1 assist in providing load carrying support for the loads placed on the deck 12.1 and the load surface 40.1 has a similar construction to the deck. The use of island formations 26.1 inside the feet 14.1 allows the pallets 10.1 to nest up to a nesting ratio of 6: 1 , yet to have sufficient continuity in the top, load carrying surface of the deck, 12.1 to support loads and to distribute the pallet load wide enough over the collective undersides of the feet 14.1 , to allow the pallets 10.1 to be double stacked (i.e. stacked on top of the loads of laden pallets).

The hollow, tapering construction of the feet 14.1 and island formations 36.1 , as well as the apertures 20.1 through the deck 12.1 allow the pallets 10.1 to be stacked, with their feet nesting inside the apertures 20.1 and cavities 26.1 of the pallet below, the island formations 36.1 extending upwards and nesting inside the island formations in the feet 14.1 of the pallet above, and with the decks 12.1 of the pallets against each other. The nesting of pallets 10.1 this way substantially reduces the overall height of the stack of pallets, reduces space requirements and thus substantially reduces the cost of storing and transporting the pallets. The taper of the feet 14.1 assists in de-nesting the pallets 10.1 .

As best seen in Figure 4, on the underside of each foot 14.1 , four male attachment formations 42.1 and four female attachment formations 44.1 are defined. Each male attachment formation 42.1 is narrower than the female attachment formations 44.1 and defines an elongate attachment aperture 46.1 on its underside. Each female attachment formation 44.1 defines an opening 48.1 on its underside that is complementally shaped to the male attachment formation 42.1 (i.e. the male attachment formation can be received snugly inside the opening). A pair of clips 50.1 are provided inside each female attachment formation 44.1 - recessed above the opening 48.1 .

The under-surfaces of the attachment formations 42.1 and 44.1 are aligned and form the under-surfaces of the feet 14.1 , so that the attachment formations also serve as support formations that can bear the load of the pallet 10.1 on a support surface. The clips 50.1 are thus recessed from the load bearing under-surfaces of the feet 14.1 and are protected inside the female attachment formations 44.1 . As shown in Figures 6 to 9, if required, one of the pallets 10.1 can be inverted, so that its feet 14.1 extend upwards from its deck 12.1 and another of the pallets 10.1 can be placed above the inverted pallet, so that the feet of the two pallets are aligned. If the two pallets 10.1 are pressed together, the male attachment formations 42.1 of each pallet are received inside the openings 48.1 of the other pallet and the clips 50.1 of each pallet pass partly through the attachment aperture 46.1 of the other pallet and grips the periphery of the attachment aperture 46.1 in a clipping manner. The result is that the attachment formations 42.1 and 44.1 of the pallets 10.1 are releasably attached to one another, with the decks 12.1 of the two pallets generally parallel to each other and with their feet 14.1 extending continuously between the decks.

If required, the pallets 10.1 can be detached from each other, by urging the pallets apart - which causes the clips 50.1 to release the peripheries of the attachment apertures 46.1 , so that the male attachment formations 42.1 can be withdrawn from the female attachment formations 44.1. The clips 50 are preferably configured so that the pallets 10.1 can be attached together and can be separated with a force of about 300N. It is thus easy to fit or remove an inverted pallet 10.1 and it can be done by hand while the upper pallet is elevated, or can be done in an automated operation, but the force required is high enough to prevent the pallets from being separated unintentionally.

As shown in Figure 9, when two of the pallets 10.1 are releasably attached together, as described above, the two pallets need not have identically shaped or sized decks 12.1 and it is envisaged that multiple pallet sizes can be provided - each with a different, standard deck size, but the feet 14.1 of the pallets spaced apart on a standard configuration - or a few standard configurations - to allow various of the pallets to be releasably attachable to one another.

In use, the pallet 10.1 can be used on its own (as shown in Figures 1 to 5) in many applications. In particular, the pallet 10.1 can be used to carry goods, can be double- stacked, and can nest - when transporting un-laden pallets. However, if required, another pallet 10.1 can be fitted to the underside of the pallet (as shown in Figures 6 to 9) - whether only for the short-term, or for the longer term. Fitting the two pallets 10.1 together enhances the bending strength of the pallets 10.1 , so that they can rack and it allows the pallets to be used on standard automated pallet handling systems. Goods loaded onto a pallet 10.1 do not need to be transferred, but can remain on that pallet while being handled in one pallet handling facility, transported and handled in a next handling facility - even if the pallet handling facilities have different strength or size requirements, because a suitably sized inverted pallet 10.1 can simply be fitted to the underside of the pallet 10.1 in each location, to allow the attached pallets 10.1 to be handled using the existing pallet handling equipment.

The heights of the pallets 10.1 can also be used beneficially, because only a single, upright pallet is required while goods are transported on the pallet and the height of the single pallet is substantially lower than the height of the combined pallets 10.1 . The reduction in pallet height means that more space is available for goods on the pallet, when the pallet is used in spaces with limited height - e.g. in standardised cargo containers.

Referring to Figures 10 to 13, pallets 10.2 of the second embodiment of the present invention, are similar to the pallets shown in Figures 1 to 9, apart from different configurations of the feet 14.2 of the pallets 10.2.

Four elongate apertures 20.2 are defined through the deck 12.2 - one above each foot 14.2. Each of the feet 14.2 has a narrow, elongate shape and the length of each foot is generally equal to the length of the deck 12.2. The term "generally equal" is intended to include lengths of the feet 14.2 that are a bit shorter than the length of the deck 12.2, as shown in the drawings.

Each foot 14.2 is hollow, with an internal cavity 26.2 that is continuous with the aperture 20.2 in the deck 12.2, immediately above the foot. The walls 28.2 of each foot 14.2 taper and the foot defines two recesses 30.2 that each extend from the underside (bottom) of the foot for about half of its height. The recesses 30.2 are spaced apart so that they can receive the tines of a lifting device such as a pallet jack. The recesses 30.2 are typically too small (typically about 50 mm high) to receive the tines of a fork lift truck comfortably, but the pallet 10 can receive the tines of a fork lift truck between the feet 14.2. As best seen in Figure 1 1 , the underside of each of the feet 14.2 also defines four male attachment formations 42.2 and four female attachment formations 44.2, alternating along the length of each foot - leaving space for the two recesses 30.2. The attachment formations 42.2 and 44.2 allow one of the pallets 10.2 to be inverted and to be attached releasably to the feet of a pallet 10.2 in an upright orientation, as shown in Figure 13 - in the same manner and with the same benefits as described above, with reference to Figures 1 to 9. However, the male attachment formations 42.2 do not define attachment apertures and the female attachment formations 44.2 do not include clips, but receive the male attachment formations in openings 48.2 with a friction lock, taper lock, or the like - preferably requiring a force of about 300N to attach and detach the attachment formations.

The hollow, tapering construction of the feet 14.2 and the apertures 20.2 through the deck 12.2 allow the pallets 10.2 to be stacked, with their feet nesting inside the apertures 20.2 and cavities 26.2 of the pallet below, and with the decks 12.2 of the pallets against each other, as shown in Figure 12. The nesting of pallets 10.2 this way substantially reduces the overall height of the stack of pallets, reducing space requirements and thus substantially reducing the cost of storing and transporting the pallets. Another advantage of the taper of the feet 14.2 is that the overall dimensions (along the periphery of the pallet 10.2) of the feet are always smaller than the overall dimensions along the periphery of the deck 12.2 and this allows for effective wrapping of palletised loads. The number of feet 14.2 and the positions of the feet can be different, depending on the load carrying ability of the pallet 10.2 that is required. In particular, if the pallet 10.2 is required to rack and/or to carry heavy loads, the number of feet 14.2 could be higher and the positions of the feet closest to the edges of the deck 12.2 could be selected to suit rail racking or edge racking.

The spacing between the feet 14.2 is such that it can allow easy access for the tines of a lifting device between them and the two feet 14.2 closest to the middle of the pallet 10.2 are spaced closer together - partly to allow adequate space for lifting tines, but also to provide stiffness to the deck 12.2 in its middle - where bending loads (and the likelihood of deflection - especially when racked) are the highest. Two handle recesses 24.2 are defined on each edge of the deck 12.2 on its underside. These handle recesses 24.2 allow easy access for hands or automated lifting equipment, to separate the pallets 10.2 if they are stacked with their decks 12.2 close together, as shown in Figure 12. Two diagonal slots 25 are defined in the deck 12.2, where identification devices such as RFID tags can be fitted.

The pallet 10 is preferably made by injection moulding of a suitably strong polymeric material - preferably a reinforced thermoplastic. Preferably, the pallet 10 is manufactured completely from recycled materials from post-consumer sources and it could include PET or recycled Polypropylene (PP) reinforced with long glass fibres - with an average fibre length in the region of 5 to 10 mm.

The deck 12.2 typically has a height (thickness) of 25 mm and the height of the feet 14.2 is typically 90 mm - to allow for entry of the tines of fork lift trucks. The overall height of the pallet 10.2 can thus be below 130 mm and it is significantly lower than the typical 175 to 180 mm of conventional wooden pallets and this reduction in height often allows an additional layer of cartons to be fitted on top of a pallet 10.2, inside a standard cargo container. Despite the low height of the pallets 10.2, they are capable of nesting up to a ratio of 1 :6.

The pallet 10.2 shown in Figures 10 to 13, has a deck 12.2 with a size of 1200 x 1000 mm and has a weight less than 14kg, preferably less than 10kg and further preferably less than 8 kg. In preferred embodiments, the pallet 10.2 can be made from PET materials reinforced with glass fibre and weigh less than 8 kg, or the pallet 10.2 can be made from PP reinforced with glass fibre and weighs less than 7 kg - yet can rack safely with a load of 600kg. In other embodiments, the pallet 10.2 has a weight of less than 15kg and can rack 1250kg safely. (By racking "safely" is meant that a safety factor of 2 has been applied - i.e. the pallets 10.2 will only break if carrying double the loads mentioned above.) The pallet 10.2 can achieve these racking loads despite being runner-less and without a bottom deck.

Referring to all the drawings, in addition to the various advantages of the pallets 10 that have been mentioned above, the pallets 10 are very light in weight and are exceptionally strong - so that they save costs in manufacturing and transport. The pallets 10 also save transport costs by nesting, by avoiding the need to transport the inverted pallets (or the "lower halves", if referring to conventional pallets), and by allowing more payload to be transported in the available space. The pallets 10 also reduce the cost of replacing broken pallets, because if one of the two pallets that have been attached together, breaks, the pallets can be separated and only the broken pallet needs to be replaced. (By comparison, if either the top deck or bottom deck of a conventional pallet breaks, the entire pallet needs to be replaced, or it can be refurbished in extensive operations.) Likewise, if pallets 10 are incorrectly jacked, the two pallets will separate, rather than breaking like conventional pallets. In addition, the invention offers versatility by providing the ability to convert a pallet 10 between a low- cost simple load-bearing pallet, to an even stronger double pallet, to a pallet with a different sized bottom and/or to pallets that can be handled in different sized standardised handling equipment - without needing to offload the pallet.