Description

The present invention is directed towards a pallet base, an intermediate bulk container, a method of assembly of an intermediate bulk container, a runner structure, and a deck structure

Intermediate Bulk Containers (IBCs) are reusable, multi-use containers configured for the transport and storage of liquids, semi-solids, pastes, or solids. There are many different types of IBC. One of the most frequently used IBC container is a caged IBC container.

A caged IBC container comprises a pallet base, a cage and a container. The container is usually arranged on top of the pallet base and surrounded by the cage to hold it in place and to support it structurally. The container is often made by thermoplastic blow mold using high-density polyethylene. The container usually comprises a top inlet port used to insert the contents of the container. In addition, a bottom outlet port in the bottom area of the container allows discharging the contents. Moreover, using a rigid cage allows stacking containers on top of each other. Even further, the cage is firmly connected to the base such that the container is held in place. The cage can be made of a steel frame, e.g. galvanized steel, or another rigid material.

The pallet base is usually made of a variety of materials, e.g. wood, plastic, steel, or any other material that is strong enough to support the filled container as well as further containers stacked on top.

The pallet base and the cage are configured such that the bottom of the pallet base may engage the cage such that lateral movement of two IBCs on top of each other is prevented. The pallet base is usually further configured such that a forklift can lift the IBC.

A problem with IBCs exists in the transport of the unused IBCs. Before using the IBC, the individual parts need to be transported and assembled. In particular, the transport of the pallet base requires a lot of space.

It is therefore an object of the present invention to make the transport of the parts of IBC containers more efficient. In particular, it is an object of the invention to reduce the space required to transport multiple pallet bases. It is further in particular an object of the invention to reduce transport costs and to facilitate easy assembly of an IBC container.

The object is solved by a pallet base according to claim 1, an intermediate bulk container according to claim 17, a method of assembly of an intermediate bulk container according to claim 18, a runner structure according to claim 19 and a deck structure according to claim 20.

The problem is in particular solved by a pallet base, in particular a pallet base of an Intermediate Bulk Container (IBC), preferably of a caged IBC container, comprising:

• a deck structure with a top surface and a bottom surface, the top surface defining a load area adapted to support an IBC container; at least one foot structure extending from the bottom surface; wherein at least one runner structure is provided, the at least one runner structure configured to engage with the at least one foot structure, preferably using a snap-fit mechanism.

A core of the invention is that the at least one runner structure is removed from the pallet base. This allows the deck structures to be stacked on top of each other, which simplifies transport. The at least one runner structure is thus removed from the deck structure and is not in the way of efficient stacking. Moreover, this further facilitates a late decision on the exact pallet base to assemble as runner structures of different kind and/or thickness may be attached to the deck structure/foot structure. Once the pallet base reaches its destination, the at least one runner structure can be assembled and connected to the deck structure. The connection between the at least one runner structure and the deck structure can either be removable or fixed.

In addition, the modular build of the pallet base allows using runner structures of different size, width and/or thickness. For example, in one embodiment at least one first runner structure may be provided with a first width and/or first height/thickness. The at least one first runner structure may thus be associated with a low duty pallet base. At least one second runner structure may be provided with a second width and/or second height/thickness. The at least one second runner structure may thus be associated with a heavy duty pallet base. The first width and/or height/thickness may be smaller than the second width and/or height.

In one embodiment the at least one foot structure may be configured as an at least substantially hollow structure such that a second foot structure of a second pallet base may be stacked on top of the pallet base and may engage into the at least one foot structure, wherein the at least one foot structure may in particular be shaped tapered away from the bottom surface.

In one embodiment the at least one foot structure defines an opening in the deck structure, such that a second foot structure of a second pallet base may be inserted into the at least one foot structure. A very efficient stacking can be achieved when the at least one foot structure of different deck structures engage with each other. Such an embodiment dramatically reduces the room requirements during transport.

In one embodiment, the at least one foot structure and the deck structure are manufactured in an integral construction.

It is possible to manufacture the foot structure and the deck structure in an integral way, for example using plastic, in particular polyethylene. This provides an efficient manufacturing process and also provides the required stability. Of course, for very high duty applications, an integral metal construction can also be envisioned. Furthermore, an integral construction provides a very high durability and has the advantage that no further assembly is required.

In one embodiment, the at least one runner structure may define at least one engagement region on a runner top surface, wherein the at least one engagement region may be adapted to at least partially contact the at least one foot structure.

By forming at least one engagement region, the connection between the at least one foot structure and the deck structure can be centralized in a particular region. This simplifies connection between the at least one runner structure and the deck structure.

In one embodiment, the at least one runner structure may comprise at least one hook extending out of a/the runner top surface, in particular in the at least one engagement region, the hook being adapted to engage with a protrusion on the at least one foot structure, in particular on the inside of the at least one foot structure.

Using a hook allows for a snap-fit connection between the at least one runner structure and the deck structure. This kind of connection is secure and easy to set-up. Moreover, after assemble, in some embodiments, the connection can be released and the pallet base can be disassembled easily. Moreover, in case the at least one runner structure or the deck structure breaks, the respective parts can be replaced easily. The hook can, of course, also be used in an embodiment with a fixed connection between the at least one runner structure and the deck structure.

In one embodiment, the at least one engagement region comprises at least one restraining wall adapted to prevent a lateral movement of the at least one runner structure relative to the at least one foot structure.

The at least one restraining wall provides a better fit and allows easy assembly. In particular, the at least one restraining wall in one embodiment can serve as a guide so the at least one runner structure engages with the deck structure as intended. Moreover, the restraining wall provides lateral stability as lateral movement is prevented.

In one embodiment, the pallet base may comprise a de-watering hole arranged in the engagement region, in particular a through-hole through the at least one runner structure.

Specifically in case the at least one foot structure is made of a hollow structure it is beneficial to have a de-watering hole. As the at least one runner structure and in particular the engagement region of said at least one runner structure may lock/seal the bottom of the at least one foot structure, a de-watering hole provides a possibility to drain rain water.

In one embodiment, the at least one runner structure may have a tapered shape with a top runner surface and a bottom runner surface, wherein the top runner surface may be narrower than the bottom runner surface.

A tapered shape of the at least one runner structure provides improved handling of the pallet base, e.g. using a forklift. The tapered structure allows the forks of the forklift to lift the pallet base without the risk of the pallet base to drop to the sides. For this, the at least one runner structure preferably has a thickness greater than 5 cm. Regular forks of a forklift may have a thickness of 5 cm. Consequently, a larger thickness of the at least one runner structure together with the tapered shape ensures that the forks of the forklift are "enclosed" by the at least one runner structure when lifting the pallet base. In one embodiment, the engagement region may be arranged on the top runner surface, the engagement region may be extending beyond an edge of the top runner surface and being configured narrower than a width of the bottom runner surface.

The aforementioned embodiment has the benefit that the engagement region may serve as a guide to the forks of a forklift such that lateral movement is prevented.

In one embodiment, the pallet base may comprise at least one reinforcement structure, arranged on, in, and/or below the deck structure, preferably extending at least along 60% of a width of the deck structure.

A reinforcement structure allows preparing the pallet base for heavy loads. Thus, it becomes possible to transform a pallet base from a low- or normal duty pallet base to a heavy duty pallet base that is able to sustain considerable loads.

In one embodiment, the deck structure may have at least one, preferably two, reinforcement recess formed inside the deck structure adapted to take a/the reinforcement structure.

The reinforcement structure may in one embodiment be a metal rod. The deck structure may in one embodiment have an opening a side surface such that the reinforcement structure may be inserted into the opening.

In one embodiment, the deck structure comprises a plurality of ribs forming a grid along the top surface and bottom surface, wherein the grid comprises a plurality of through holes from the top surface to the bottom surface.

Using a grid for the deck structure has the advantage that the entire structure becomes lightweight. Moreover, the structure is very stable and liquid can pass through it.

In one embodiment, the deck structure may have a plurality of cage connection regions adapted to be attached to a cage, in particular a plurality of threads for screws, arranged on an outer edge of the deck structure. A cage may be connected on top of the deck structure which may hold a container that contains liquid or any other goods to be transported. The cage thus provides a means to hold the container on the deck structure. Moreover, the cage allows stacking multiple containers on top of each other.

In one embodiment, the at least one runner structure may run substantially straight in parallel to the bottom surface of the deck structure when engaged with the at least one foot structure.

In one embodiment, a plurality of foot structures together with respective runner structures may form at least three runner rows on the bottom surface of the deck structure, wherein the rows are distanced such that a fork, for example of a forklift or a low lift pallet truck, is insertable between the rows and lift the pallet base.

With three rows, a forklift can easily lift the pallet base. Still more or fewer rows are conceivable in further embodiments of the invention.

The object of the invention is further in particular solved by an Intermediate bulk container, in particular a caged IBC container, comprising:

• a pallet base as defined in any of the preceding embodiments;

• a cage;

• a container, wherein the container is arranged within the cage and the cage is joined with the pallet base.

The object of the invention is further in particular solved by a method of assembly of an Intermediate Bulk Container, the method comprising the following steps:

• Attaching at least one runner structure of a pallet base to a deck structure, in particular a runner structure and/or a deck structure of a pallet base of any of the preceding embodiments;

• Arranging a cage on the deck structure;

• Joining the cage with the deck structure; Placing a container on a load surface of the deck structure inside the container.

The steps of the above method can be performed in any order. In particular, it is envisioned that the attaching of the at least one runner structure can be perfomed as the first or the last step of the method.

In one embodiment, the joining may be performed by inserting screws into threads of the deck structure.

The object of the invention is further in particular solved by a runner structure of the pallet base according to any of the preceding embodiments.

The object of the invention is further in particular solved a deck structure of the pallet base according to any of the preceding embodiments.

Further embodiments are indicated in the dependent claims.

In the following, embodiments of the invention are described with respect to the accompanied drawings, where the figures show:

Figure la: a diagonal view on a caged IBC container;

Figure lb: a side view of a caged IBC container;

Figure 2: a diagonal view of a runner structure;

Figure 3: a cross section of a runner structure;

Figure 4: a side view of a deck structure;

Figure 5: a diagonal view of a deck structure;

Figure 6: an example of stacking a plurality of deck structures;

Figure 7: a flow diagram of a method of assembly; and Figure 8: an exploded view of a caged IBC container.

In the following, the same reference numerals refer to similar parts.

Figure la shows a diagonal view of a caged IBC container 1, the caged IBC container comprising a cage 2, a container 3, a deck structure 20 as well as a plurality of runner structures 10.

The container 3 is arranged within the cage 2 and comprises a top port 4, by which liquid or powder may be inserted into the container 3. In addition, the container 3 comprises a bottom port 5, which can be used to drain the contents of the container 3. The bottom port 5 is arranged at least substantially in the middle between 2 sidewalls of the container and is accessible through the cage 2. Moreover, the bottom port 5 may comprise a handle to open a valve in order to drain the contents of the container 3. The container 3 in the present embodiment is made of plastic, in particular of Polyethylene.

The cage 2 is made of metal and is adapted to support the structure of the container 2. In particular, the cage 2 prevents the container 3 from expanding beyond the cage 2. Moreover, the cage 2 allows stacking multiple IBC containers 1 above each other by providing the required stiffness and stability even when the container 3 is empty. In the region of the bottom port 5 of the container 3, the cage 2 has a recess in the metal frame in order to allow passage and optionally the attachment of a hose to the bottom port 5. As a result, the shown cage 2 is directed and only fits onto the container 3 in a pre-defined way. More in particular, in case the bottom port 5 extends beyond the perimeter of the cage 2, the container 3 needs to be placed onto a deck structure 20 prior the assembly of the cage 2.

The IBC container 1 further comprises the deck structure 20 with a top surface, which defines a load area 27 (see figure 5). The container 3 is arranged to rest on the load area 27. Below the deck structure 20, a plurality of runner structures 10 is arranged. The runner structures 10 are therefore the structures on which the IBC container 1 rests when put on the ground.

Figure lb shows a side view of the IBC container 1 as shown in figure la. Figure lb shows that a pallet base 8 comprises a deck structure 20 as well as at least one runner structure 10. As is evident from figure lb, the deck structure 20 comprises a plurality of foot structures 21, which extend away from a bottom surface of the deck structure 20 and which are connected to the runner structures 10. The runner structures 10 are in particular removably connected with the foot structure 21.

Figure 2 provides a detailed view on an embodiment of a runner structure 10. The runner structure 10 comprises three engagement regions 11, each engagement region 11 comprising a plurality of restraining walls 12, 12'. The restraining walls 12, 12' are arranged around the outer edges of the engagement region 11. Each engagement region 11 is adapted to engage with a foot structure 21 of the deck structure 20. As a result, the restraining walls 12, 12' prevent a lateral movement of the runner structure 10 with respect to the deck structure 20.

Figure 3 shows a cross-section of a runner structure 10 and details of the proposed engagement mechanism. The runner structure 10 of figure 3 has a generally tapered shape with a bottom surface 16 and a top surface 15. The bottom surface 16 has a bottom width W2 and the top surface 15 has width Wl. The bottom width W2 is greater than the top with Wl and thus the shape is tapered. Preferably, the ratio of the top width Wl and the bottom width W2 is 2/3. The top surface 15 and the bottom surface 16 are distanced by a height H, which may vary according to the load requirements. Still, the height H may be chosen such that it is more than the height of a fork of a forklift, e.g. greater than 5cm. By this, it is ensured that the fork engages above the bottom surface, e.g. two parallel arranged runner structures 10 enclose the fork.

The tapered shape of the runner structure 10 has the advantage that the forks of a forklift may engage with the runner structure 10 such that the IBC container 1 is securely held. To achieve this secure fit, runner structure 10 further comprises two restraining walls 12, 12', which each have an outer guide surface 17, against which may contact the forks of a forklift. In one embodiment, the height of the restraining wall 12, 12' may be greater than 5cm, i.e. greater than the height of a fork of a forklift. Thus, the tapered shape of the runner structure 10 prevents the IBC container 1 to tilt when lifted by a forklift. Thus, dropping of the IBC container 1 of the fork lift is efficiently prevented. To removably connect the runner structure 10 with a foot structure 21 of the deck structure 20, the runner structure 10 comprises at least two hooks 13, which extend from the top surface 15 of the runner structure 10. Each hook 13 is adapted to engage with a respective protrusion of the foot structure 21. Thus, the at least one runner structure 10 is connected to a respective at least one foot structure 21 of the deck structure 20 with a snap-fit mechanism.

In addition, the runner structure 10 comprises a de-watering hole 14, which is formed as a through hole along the height of the runner structure 10. The dewatering hole 14 is beneficial as the top surface 15 of the runner structure 10 seals the bottom of a respective foot structure 21 when the two are connected. Thus, without the de-watering hole 15, rain water might fill the foot structure 21 of the deck structure 20, which leads to material degradation in the long run.

Figure 4 illustrates a side view of a deck structure 20. The deck structure 20 comprises on its top surface 28 a plurality of threats 23, which are arranged at the outer perimeter of the top surface 28 of the deck structure 20. Those threats 23 can be used to attach a cage 2 with the deck structure 20. As a result, the cage 2 is firmly fixed to the deck structure 20.

In order to securely fit a container 3 onto the deck structure 20, the deck structure 20 comprises a delimiter wall 22 around the perimeter of the top surface 28 of the deck structure 20. The delimiter wall 22 may be shaped with a increasing inclination from the centre of the top surface 28 to an edge of the top surface 28 of the deck structure 20. The delimiter wall 22 may in particular be shaped such that it corresponds to the shape of a container 3 which may be stacked on top of the top surface 28 of the deck structure 20. As a result, the container is held in place and lateral movement of the container when no cage 2 is attached to the deck structure 20 is prevented.

Figure 4 further illustrates that the deck structure 20 may comprise three foot structures 21, 21', 21" extending from a bottom surface 29 and which may engage with a runner structure 10. Consequently, the food structures 21, 21', 21" define a row. For the deck structure 20 as shown, it is envisioned that a total of three lines of food structures 21, 21', 21" are part of the deck structure 20. Each foot structure 21, 21', 21" is adapted to engage with a runner structure 10. For this purpose, a foot structure 21" comprises at least one guide region 24, 24' on an outer surface of the foot structure, the outer surface in particular being arranged at least substantially perpendicular to a ground plane. In the shown example, a foot structure 21" comprises 2 guide regions 24, 24". The guide regions 24, 24' are adapted to engage with a corresponding runner structure 10. Preferably, the guide regions 24, 24' are formed as recesses that correspond in shape to the restraining walls 12, 12' of a runner structure 10. Thus, the restraining walls 12, 12' may fit into the guide regions 24, 24' and thus guide the runner structure 10 when attaching to the deck structure 20.

The deck structure 20 of figure 4 further comprises a reinforcement structure 40, which is arranged inside the deck structure 20. For this, the deck structure 20 has an reinforcement opening 42 through which the reinforcement structure 40 can be inserted. In the shown embodiment, the reinforcement structure 40 is configured as a metal rod.

Figure 5 shows a deck structure 20 in a diagonal view. As is evident from figure 5, the deck structure 20 comprises three rows of foot structures 21 - the rows indicated by the shown arrows, each row comprising three foot structures 21. Via each row of foot structures 21, one runner structure 10 attaches to the deck structure 20.

The deck structure 20 further defines a load area 27 , which is defined on the top surface 28 of the deck structure 20. In the shown embodiment, the load area 27 is a solid area, covering the upper surface of the deck structure 20. Still, in further embodiments, the load area 27 can also be made of a grid structure. As is evident, the load area 27 defines openings 25 into respective foot structures 21. In addition, the load area 27 has a recess at the bottom port engagement region 26. The bottom port engagement region 26 is adapted to house a bottom port 5 of a container 3. Moreover, below the bottom port engagement region 26, a foot structure 21 is arranged.

In addition, figure 5 shows two reinforcement structure 40, 40', each reinforcement structure 40, 40' arranged in a corresponding reinforcement recess 41, 41' inside the deck structure 20. The reinforcement structure 40, 40' is used to further stiffen the deck structure 20. Thus, by incorporating reinforcement structures 40, 40', the deck structure 20 can be modified to support a higher load of goods. A reinforcement structure 40, 40' can be shaped as a metal or steel rod. In particular, a reinforcement structure 40, 40' can be made as an elongated bar/rod. To easily integrate the reinforcement structure 40, 40' into the deck structure 20, a reinforcement opening 42, 42' can be provided in the deck structure 20 through which the reinforcement structure 41, 41' can be inserted into a reinforcement recess 41, 41' of the deck structure 20. Different reinforcement structures 40, 40' may be used that differ in thickness and/or material in order to fulfill different stiffness requirements.

Figure 6 illustrates how multiple deck structures 20, 20', 20" can be stacked on top of each other. Figure 6 shows a total of three deck structures 20, 20', 20". The first deck structure 20 is already stacked on top of the second deck structure 20'. In the shown embodiment, the first and the second deck structure 20, 20' are about to be stacked on a third deck structure 20".

Due to the fact that no runner structures 10 need to be attached to the deck structures 20, 20', 20" prior assembly, the foot structures 21 of deck structure can be inserted into openings 25 of the deck structure 20" to rest within the foot structure 21' of the underlying deck structure 20".

In this way, the described deck structures 20, 20', 20" utilize a minimum of space during transport. This simplifies the transport and allows cost savings as well as reduces the storage room required prior assembly of an IBC container 1.

Figure 7 shows a flow diagram of a method of assembly 30 of an IBC container 1. In a first attaching step 31, at least one runner structure 10 is attached to a deck structure 20 of a pallet base 8. Preferably, three runner structures 10 are attached to a total of nine foot structures 21, defining three rows and two channels to take forks of a forklift.

After attaching the runner structures 10, in an arranging step 33, a cage 2 is arranged on the deck structure 20 . This can be done by drilling screws through the cage 2 into respective threads 23 of the deck structure 20.

In a next placing step 34, a container 3 is placed on the deck structure 20 of the pallet base 8 inside the cage 2. The placing is performed such that any bottom port 5 of the container 3 is placed into a respective recess in the deck structure 20 of the pallet base 8.

Figure 8 once more illustrates an exploded view of an ICB container 1, comprising of a container 3, a cage 2 and a pallet base 8 comprising of a deck structure 20 and three runner structures 10.

As is evident from figure 8, the cage 2 comprises a top opening 6 and a bottom opening 7. The bottom opening 7 is used to lift the cage 2 over the container 3 in case the container comprises a bottom port 5. Of course it is possible in one embodiment that the top opening 6 is left out and the cage 2 may thus be a closed cage 2 without a top opening 6.

At this point it should be noted that all parts described above that are individually identifiable - even without additional features described in the respective context, even if these are not explicitly identified as optional features in the respective context, e.g. by using: in particular, preferably, for example, e.g., if necessary, , round brackets, etc. - and in combination or any sub-combination are to be regarded as independent features or further developments of the invention, as defined in particular in the introduction to the description and the claims. Deviations from this are possible. Specifically, it should be noted that the word in particular or round brackets do not indicate any features that are mandatory in the respective context.

Reference numerals:

1 Caged ICB container

2 Cage

3 container

4 top port

5 bottom port

6 top cage opening

7 bottom cage opening

8 pallet base

10 runner structure

11 Engagement region

12, 12' restraining wall 13 Hook

14 de-watering hole

15 Runner top-surface

16 Runner bottom -surface

17 Outer guide surface

18 Inner guide surface

20, 20', 20" deck structure

21, 21', 21" Foot structure

22 Delimiter wall

23 Thread

24, 24' Guide region

25 Opening

26 Bottom port engagement region

27 Load area

28 Top surface

29 Bottom surface

40, 40' reinforcement structure/rod

41, 41' reinforcement recess

42, 42' refinforcement opening 30 Method of assembly

31 Attaching step

34 Placing step

32 Arranging step

33 Joining step

Wl, W2 Width

H Height