Skeleton pallets with optional faceboards
A pallet is created from two sets of thin stringers crossing and mated orthogonally, forming forkway notches and including ribs to guide the fingers of lifting machinery through the pallet. The pallet may include an optional mortised deck.
The technical field generally relates to portable platforms. More specifically, the technical field relates to a pallet for handling, storing, or moving materials and packages manipulable with a lifting machine.
BACKGROUNDPallets, sometimes colloquially referred to as “skids,” were slowly introduced during the 20th century in order to facilitate the transportation of goods. Before the introduction of pallets, goods to be shipped were placed in boxes, crates, or barrels. These containers had to be loaded or unloaded from the shipping vehicle by hand one at a time, a very time-consuming and dangerous process. Now, materials can be combined together with straps, shrink wrap, or some other means into a unit load, placed on a pallet, and then manipulated as a unit with a wide variety of lifting machines, such as forklifts or hand trucks. Pallets thus allow materials to be transported much more safely and efficiently than before. The usefulness of pallets is shown by their ubiquity: around five hundred million pallets are constructed in the United States each year, and almost two billion pallets are in use in the United States at any time.
Pallets are commonly constructed from a variety of materials, including plastic, corrugated fiber, and steel. The most often used material for constructing a pallet is wood: over 90 percent of the pallets in use are so constructed. The materials handling industry is one of the largest domestic consumers of wood fiber and timber, consuming more timber (approximately 70 million tons) per year than the paper, home construction, or home repair industries. Pallets come in a variety of designs in order to meet the demands of the particular application for which they are intended. For instance, a pallet destined to carry a particularly heavy load would need to be particularly strong, a pallet destined to carry a load on an airplane would need to be particularly light and a pallet destined to be produced in large quantities would need to be particularly inexpensive and recyclable. Thus, the choice of design and building material will often depend on the intended application.
SUMMARYThis summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. In accordance with this invention, several forms of the invention including a pallet, a deck, and a method for construction are provided.
The pallet form of the invention comprises a set of lower stringers that are spaced apart. Each lower stringer includes a set of outer slots, a set of inner slots, and a set of projections. Each projection is situated at either a distal end or a proximal end of a lower stringer. Each outer slot is adjacent to a projection, each inner slot being adjacent to an outer slot. The pallet also comprises a set of upper stringers that are spaced apart. Each upper stringer includes a set of outer slots, a set of inner slots, a set of rib slots, a set of notches, and a set of projections. Each projection being situated at either a distal end or a proximal end of an upper stringer. Each outer slot is adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end. Each rib slot is situated at approximately the center of each notch. The pallet further comprises a set of ribs that sit into the set of rib slots of the upper stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load. The sets of outer slots engage one another and the set of inner slots engage one another to form forkways by the set of notches. From the set of rib slots, the set of ribs protrude into the forkways to guide fingers of lifting machinery so the pallet may be possessed.
In accordance with further aspects of this invention, a pallet that includes a deck is provided. The pallet comprises a set of lower stringers that are spaced apart. Each lower stringer includes a set of outer slots, a set of inner slots, and a set of projections. Each projection is situated at either a distal end or a proximal end of a lower stringer. Each outer slot is adjacent to a projection, each inner slot being adjacent to the outer slot. The pallet further comprises a set of upper stringers that are spaced apart. Each upper stringer includes a set of outer slots, a set of inner slots, a set of notches, and a set of projections. Each projection is situated at either a distal end or a proximal end of an upper stringer. Each outer slot is adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end. The pallet also includes a deck which bottom is cut to form a set of mortises. A first subset of the mortises is spaced apart and a second subset of the mortises being spaced apart and orthogonal to the first subset of the mortises, the set of mortises receiving a structure created when the sets of upper stringers and lower stringers are orthogonally mated so as to reduce racking.
In accordance with further aspects of this invention, a method form of the invention includes a method for manufacturing a pallet is provided. The method includes obtaining lumber of approximate four-inch height and appropriate width and length; configuring the teeth of a saw to cut notches and slots in the lumber; using the saw to cut the notches and slots in the lumber in appropriate locations for a set of upper stringers; using the same saw to cut similar notches and slots in the lumber in appropriate locations for a set of lower stringers; using a different saw to divide the notched lumber lengthwise into pieces of approximate four-inch height and approximate one-half-inch width; arranging the upper stringers and lower stringers orthogonally in an interlocking manner; creating a set of ribs; and attaching the set of ribs.
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
Several issues arise in the construction of pallets. The first issue concerns the particular characteristics of the lumber chosen as construction material. Certain types of lumber are more economical to manufacture or purchase on the open market than others. However, less expensive lumber is often more difficult to form into a pallet of the necessary dimensions or strength for a given application. The second issue is that of recyclability. A wooden pallet will better resist racking, the torsional displacement of the pallet structure, by nailing the components together. However, the presence of nails makes the pallet less amenable to simple recycling techniques. The third issue is that of maneuverability. Many wooden pallet designs are “two-way,” which allow the fingers of a forklift or other lifting machinery to enter the pallet from only one direction. Some other designs are “four-way,” which allow the fingers to enter the pallet from any side, but some of those designs require the fingers to be set to different widths in order to enter a different side. Yet another issue is that of repairability. The fingers often wound the structural members of the pallet, contacting them in unintended ways and causing damage. Not all pallet designs allow for the pallet to be easily repaired, and instead they must be discarded when any piece of the structure is damaged. Various embodiments of the present invention focus on a pallet constructed out of thin, mutually notched stringers; an optional deck to provide structural support and load distribution; and methods for construction and repair of the pallet.
The lower stringers 1a-1e have notches 3 that allow the fingers of a forklift or other lifting machinery to pass through the pallet. The upper stringers 2a-2e also contain notches 7 that allow the fingers of a forklift or other lifting machinery to pass through the pallet.
The lower stringers 1a-1e and upper stringers 2a-2e fit together such that the ends of the lower stringers create projections 4 that extend past the outer upper stringers 2a, 2e so as to laterally guide the fingers of a forklift or other lifting machinery through the pallet, and such that the ends of the upper stringers 2a-2e create projections 8 that extend past the outer lower stringers 1a, 1e so as to laterally guide the fingers of a forklift or other lifting machinery through the pallet. Notably, the notches 7 in the upper stringers 2a-2e further have slots 13, as visible in
The intersections of each lower stringer 1a-1e with each upper stringer 2a-2e are preferably cut into slots 9, 10, 11, and 12, as visible in
Some embodiments of the pallet may be flipped over, such that the notches 7 and guide ribs 6 in the upper stringers 2a-2e as visible in
The construction of an embodiment of the pallet may use very lightweight and economical materials in its construction. Recognizing that various embodiments need not be limited to the following materials or dimensions, the preferred material for use to manufacture the stringers is a fast-growth timber product, such as low-grade two-by-fours created from black poplar trees. A squared piece of lumber 17 as shown in
The pallet should be reasonably stable when assembled due to the snug fit of the notches and mortises. For added stability, it is preferred to use fastening means to reinforce each joint. The preferred means is to glue each joint and each mortise, as this can provide for the easiest recyclability, but other means such as nails or staples could also be used.
From Terminal A (
From exit Terminal B (
From exit Terminal D (
From exit Terminal F (
It will be appreciated by one skilled in the art that instead of obtaining timber from forest land 15010, 15020 and squaring it off 15012, 15022 to obtain the necessary lumber, this process can use lumber of similar dimensions purchased on the open market as time and economics require.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
Claims
1. A pallet, comprising:
- a set of lower stringers that are spaced apart, each lower stringer including a set of outer slots, a set of inner slots, and a set of projections, each projection being situated at either a distal end or a proximal end of a lower stringer, each outer slot being adjacent to a projection, each inner slot being adjacent to an outer slot;
- a set of upper stringers that are spaced apart, each upper stringer including a set of outer slots, a set of inner slots, a set of rib slots, a set of notches, and a set of projections, each projection being situated at either a distal end or a proximal end of an upper stringer, each outer slot being adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end, each rib slot being situated at approximately the center of each notch; and
- a set of ribs that sit into the set of rib slots of the upper stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load, the sets of outer slots engaging one another and the set of inner slots engaging one another to form forkways by the set of notches, from the set of rib slots the set of ribs protruding into the forkways to guide fingers of lifting machinery so the pallet may be possessed.
2. The pallet of claim 1, wherein the set of lower stringers is secured to the set of upper stringers with fastening means.
3. The pallet of claim 2, wherein the fastening means includes glue.
4. The pallet of claim 1, wherein each of the ribs situated in the rib slots of the upper stringers is one solid piece of material that runs substantially from one edge of the pallet to another edge of the pallet.
5. The pallet of claim 1, wherein each stringer is of approximate half-inch thickness with the thickness disposed horizontally and of approximate four-inch width with the width disposed vertically.
6. The pallet of claim 5, wherein each stringer is created from a two-by-four or four-by-four that has been cut lengthwise into substantially equal-sized pieces of approximate half-inch thickness and of approximate four-inch width.
7. The pallet of claim 1, further comprising a repaired stringer that includes a set of outer slots, a set of inner slots, and a set of projections, the repaired stringer being fastened adjacent to either a lower stringer or an upper stringer that is injured.
8. The pallet of claim 1, wherein each of the lower stringers includes a set of notches, each notch being adjacent to an outer slot at one end and to an inner slot at another end such that when the set of lower stringers and the set of upper stringers are orthogonally mated to cause the sets of outer slots to engage one another and the set of inner slots to engage one another, forkways are formed by the set of notches.
9. The pallet of claim 8, wherein each of the lower stringers includes
- a set of rib slots, each rib slot being situated at approximately the center of each notch; and
- a set of ribs that sit into the set of rib slots of the lower stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load, and to cause the sets of outer slots to engage one another and the set of inner slots to engage one another to form forkways by the set of notches, from the set of rib slots of the lower stringers the set of ribs protruding into the forkways to guide fingers of lifting machinery so the pallet may be possessed.
10. The pallet of claim 9, wherein each of the ribs situated in the rib slots of the lower stringers is one solid piece of material that runs substantially from one edge of the pallet to another edge of the pallet.
11. The pallet of claim 10, wherein the ribs situated in the rib slots of the lower stringers and the ribs situated in the rib slots of the upper stringers are mortised at their intersections and interlock orthogonally.
12. A pallet, comprising:
- a set of lower stringers that are spaced apart, each lower stringer including a set of outer slots, a set of inner slots, and a set of projections, each projection being situated at either a distal end or a proximal end of a lower stringer, each outer slot being adjacent to a projection, each inner slot being adjacent to the outer slot;
- a set of upper stringers that are spaced apart, each upper stringer including a set of outer slots, a set of inner slots, a set of notches, and a set of projections, each projection being situated at either a distal end or a proximal end of an upper stringer, each outer slot being adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end; and
- a deck which bottom is cut to form a set of mortises, a first subset of the mortises being spaced apart and a second subset of the mortises being spaced apart and orthogonal to the first subset of the mortises, the set of mortises receiving a structure created when the sets of upper stringers and lower stringers are orthogonally mated so as to reduce racking.
13. The pallet of claim 12, wherein the deck is dimensioned substantially the same as the horizontal length and width of the pallet.
14. The pallet of claim 12, wherein the deck is secured to the pallet via fastening means.
15. The pallet of claim 14, wherein the fastening means includes glue.
16. The pallet of claim 12, wherein the deck is formed from planks of the same material used to create the rest of the pallet.
17. A method for manufacturing a pallet, comprising:
- obtaining lumber of approximate four-inch height;
- configuring the teeth of a saw to cut notches and slots in the lumber;
- using the saw to cut the notches and slots in the lumber in appropriate locations for a set of upper stringers;
- using the same saw to cut similar notches and slots in the lumber in appropriate locations for a set of lower stringers;
- using a different saw to divide the notched lumber lengthwise into pieces of approximate four-inch height and approximate one-half-inch width;
- arranging the upper stringers and lower stringers orthogonally in an interlocking manner;
- creating a set of ribs; and
- attaching the set of ribs.
18. The method of claim 17, wherein the lumber is low-grade two-by-fours;
19. The method of claim 17, wherein the lumber is obtained by squaring off timber from a fast-growth species of tree;
20. The method of claim 19, where the species of tree is black poplar.
Type: Application
Filed: Aug 25, 2006
Publication Date: Feb 28, 2008
Inventor: Stewart Ferguson (Pacific Beach, WA)
Application Number: 11/509,957
International Classification: B65D 19/16 (20060101);