STACKABLE PALLET SYSTEM HAVING FOLDABLE END BOARDS

Abstract

A stackable pallet system for storing and transporting a core-wound roll having a core, the pallet system includes a pallet, a pair of foldable end boards connected to the pallet and a pair of core supports, each disposed on an end board. The pallet includes a platform having a length, a width, a top surface and two longitudinal ends. When the pair of end boards are erected, they are disposed substantially in a parallel configuration and at substantially right angle to the platform. When the pair of end boards are folded, they are disposed substantially parallelly to the top surface; and a pair of core supports. Each end of the core is supported on one of the pair of core supports.

Description

PRIORITY CLAIM AND RELATED APPLICATIONS

This non-provisional application claims the benefit of priority from provisional application U.S. Ser. No. 61/808,182 filed on Apr. 3, 2013, provisional application U.S. Ser. No. 61/873,866 filed Sep. 5, 2013 and provisional application U.S. Ser. No. 61/937,769 filed on Feb. 10, 2014. Each of said applications is incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. The Field of the Invention

The present invention is directed generally to pallet systems and related end supports. More specifically, the present invention is directed to a pallet system with mating end boards for core-wound rolls of paper, thin films and other materials.

2. Background Art

Pallet systems have long been known in the transportation art as a quick and efficient way of transporting and storing materials that are core-wound on large rolls. These are especially useful in the flexible films industry for Oriented Polypropylene Film (OPP), Polyethylene (PE), Polypropylene (PP), Biaxially Oriented Polypropylene (BOPP), C-Methionine-PET (METPET) and other laminations of flexible structures. The core-wound rolls of material are manufactured in various widths and roll diameters. These rolls of material are typically wound on paper, phenolic or metal cores. The material is best protected by suspending it with supports on each end of the roll, attached via the core. Thus, the typical method used for storing and transporting these large rolls of material includes (1) particleboard or plastic end boards, (2) a wood pallet, (3) four metal clips, and (4) plastic or paper core inserts. These separate components are adapted by the user to work together as efficiently as possible.

The flexible films industry traditionally uses a particleboard (sawdust and glue) for end boards (also referred to as end supports) to support the various types of rolled films and laminations. The particleboard material is typically produced in 1 inch thick boards that are cut into squares or rectangles with center holes (nominal 6 inch outer diameter). The end boards are fitted onto the open core with plastic or paper end plugs that fit through the center hole of the particleboard. The particleboard end boards, with the suspended roll therebetween, are placed on a pallet system, typically a wood pallet with adequate deck boards to support the weight of the roll. The pallet surface is flat on top and bottom. The particleboard is fitted with U-shaped metal clips that have a serrated surface to create friction. The serrations “bite” into the wood deck to help keep it in place.

Plastic strapping is used to secure the roll to the end boards and the wood pallet. Product documents and shipping documents are typically stapled onto the flat surface of the particleboard.

There are known drawbacks and limitations with these prior art pallet systems and end boards. For example, stacking of two pallet systems is generally contraindicated in truck shipments because the top pallet system is not adequately prevented from movement. When the top pallet system falls onto the lower pallet system, the film is easily and badly damaged, resulting in loss of the material and production time.

Another drawback is that particleboard is not an ideal material for the end supports. Similar concerns exist for the wood pallets. Contamination from wood fiber is unacceptable in food and medical applications. This is especially challenging since films are frequently used for these applications. The particleboard has a strength limit with respect to rolls having an outer diameter greater than 46 inches and is prone to swelling when exposed to wet environments. The particleboard is heavy, prone to chipping and breaking and has sharp edges from the saw cutting process.

U.S. Pat. No. 6,994,291 to Kemp et al. discloses an end board for a core wound roll product packaging system that is proprietary. It is plastic and configured to allow for nesting of end boards to one another. It does not allow for nesting or attachment to a pallet. The nesting is due to interlock lugs, however, the interlock lug design reduces the contact surface area and resulting friction. This results in increased instability and sliding on the pallets during use.

Thus, there is a need for a device, system and method which overcomes these limitations and drawbacks of the prior art and improves the process of storing and transporting large rolls of material.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided a stackable pallet system for storing and transporting a core-wound roll having a first core, the pallet system including:

• • (a) a pallet comprising a platform having a length, a width, a top surface, a bottom surface and two longitudinal ends;
  • (b) a pair of end boards, where each end board is pivotably connected to one of the two longitudinal ends of the platform such that when the pair of end boards are erected, the pair of end boards are disposed substantially in a parallel configuration, each of the pair of end boards is disposed at substantially right angle to the platform and when the pair of end boards are folded, the pair of end boards are disposed substantially parallel to the top surface of the platform; and
  • (c) a pair of core supports, where each of the pair of core supports is disposed on one of the pair of end boards, where each end of the first core is supported on one of the pair of core supports.

The stackable pallet system further includes at least one glide structure configured to be glideable along at least one glide track disposed on the platform, the at least one glide structure is configured to be disposed on one of the two longitudinal ends, where at least one of the pair of end boards is pivotably connected to the at least one glide structure such that the distance between the pair of end boards is adjustable.

The stackable pallet system further includes a glide strip disposed between the glide structure and the platform, where the glide strip is adapted to facilitate the gliding of the glide structure with respect to the platform. In one embodiment, each of the pair of core supports includes a removable cradle adapted to receive each end of the first core.

In one embodiment, the removable cradle is a curvilinear portion having two ends and a central portion, each end of the curvilinear portion is terminated with a tab and a third tab is disposed at the central portion protruding outwardly from the central portion and each of the pair of core supports includes slits adapted to receive the tabs such that the removable cradle is removably attached to one of the pair of core supports.

In one embodiment, each of the pair of end boards further includes:

• (a) a hook rotatably mounted to each of the pair of end boards such that the plane of rotation of the hook is substantially parallel to the end board to which the hook is attached; and
• (b) at least one opening disposed on a portion of the platform and configured for receiving a portion of the hook,
  where when the hook is disposed in a first rotational position, the portion of the hook is disposed within the opening, immobilizing the end board to which the hook is attached and when the hook is disposed away from the first rotational position, the rotation of the end board is not restricted.

In one embodiment, each the core support further includes a core retainer capable of removable attachment to each of the pair of end boards, the core retainer is adapted to secure one end of the first core from a direction substantially opposite that of each the core support. In one embodiment, the core retainer further includes a retainer lip pivotably attached to a portion of the core retainer and the retainer lip is adapted to extend the reach of the retainer clip in a direction toward each the core support to accommodate a second spindle having a smaller diameter than the first core.

The stackable pallet system further includes a plurality of retaining brackets, each retaining bracket disposed at a bottom corner of the platform such that when disposed atop a second stackable pallet system with erected end boards, two of the plurality of retaining brackets are disposed on one of the two longitudinal ends and cooperate to encompass an open edge of one of the pair of end boards of the second pallet system.

The stackable pallet system further includes a plurality of tabs, each tab disposed at a top corner of the platform such that when disposed below a second stackable pallet system each of the plurality of tabs engages a retaining bracket disposed at a bottom corner of the second pallet system. In one embodiment, each of the pair of end boards further includes at least one recessed pocket disposed on at least one edge of each of the pair of end boards.

The stackable pallet system further includes a pair of end board limiters, each end board limiter is disposed adjacent each the end board and configured to restrict rotation of each the end board to about 90 degrees with respect to the top surface of the platform.

The stackable pallet system further includes a plurality of pads, where each of the plurality of pads is disposed at a bottom corner of the platform such that when disposed atop a second stackable pallet system with erected end boards, each of the plurality of pads provides friction surface to engage a corner of an open edge of an end board of the second stackable pallet system upon which the stackable pallet system is disposed.

The stackable pallet system further includes a plurality of strapping ports disposed on the top surface of the platform to facilitate strapping of the stackable pallet system. The stackable pallet system further includes a plurality of teeth disposed on a portion of an open edge of each of the pair of end boards. In one embodiment, the stackable pallet system is constructed from a material selected from the group consisting of steel, aluminum and plastic.

An object of the present invention is to provide a pallet system having end boards that are foldable for compact stacking, storage and transport of the system while it is not in use.

Another object of the present invention is to provide a pallet system having attached (integral) end boards that are foldable for compact stacking, storage and transport of the system and end boards that can be erected easily in preparing the system for use.

Another object of the present invention is to provide a pallet system that is stackable without requiring precise alignment of a top pallet system onto a bottom pallet system.

Another object of the present invention is to provide a pallet system that is stackable to form a laterally secure stack.

Another object of the present invention is to provide an improved pallet that eliminates the wood fiber debris of conventional pallets and end boards.

Another object of the present invention is to provide an improved end board that is stronger than conventional end boards and is not subject to deformation from moisture.

Another object of the present invention is to provide a system of mating interlocking pallets and end boards.

Another object of the present invention is to provide an interlocking pallet such that two or more pallets may be efficiently disposed adjacent to one another and stacked.

Another object of the present invention is to provide a pallet and end board that minimizes slippage during transportation and storage.

Whereas there may be many embodiments of the present invention, each embodiment may meet one or more of the foregoing recited objects in any combination. It is not intended that each embodiment will necessarily meet each objective. Thus, having broadly outlined the more important features of the present invention in order that the detailed description thereof may be better understood, and that the present contribution to the art may be better appreciated, there are, of course, additional features of the present invention that will be described herein and will form a part of the subject matter of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 is a top perspective view a first embodiment of the present pallet system, depicting two stacked and assembled end board-interlocking pallet assemblies.

FIG. 2 is a top perspective view of one of the stacked assemblies depicted in FIG. 1 without a roll.

FIG. 3 is a perspective view of an end board.

FIG. 4 is a front orthogonal view of an end board.

FIG. 5 is a side orthogonal view of an end board.

FIG. 6 is a bottom orthogonal view of an end board.

FIG. 7 is a partial enlarged bottom perspective view of one corner of an end board.

FIG. 8 is a rear face orthogonal view of an end board.

FIG. 9 is a top perspective view of an interlocking pallet.

FIG. 10 is a top orthogonal view of an interlocking pallet.

FIG. 11 is a bottom orthogonal view of an interlocking pallet.

FIG. 12 is a partial enlarged top perspective view of one corner of an interlocking pallet.

FIG. 13 is a partial enlarged top orthogonal view of one corner of an interlocking pallet.

FIG. 14 is a partial front orthogonal view of one corner of an interlocking pallet.

FIG. 15 is a partial enlarged side orthogonal view of one corner of an interlocking pallet showing the rolled edge of the decking.

FIG. 16 is a front orthogonal view of an interlocking pallet.

FIG. 17 is a side orthogonal view of an interlocking pallet.

FIG. 18 is a partial top perspective view of a corner of an assembled end board and interlocking pallet.

FIG. 19 is a partial side orthogonal view of a corner of an assembled end board and interlocking pallet.

FIGS. 20 and 21 are a top perspective and bottom perspective view, respectively, of a second embodiment of the present pallet system featuring open core supports and foldable end boards.

FIGS. 21A and 21B are a partial top perspective view of two folded and erected pallet systems, respectively, with the end board limiter removed to reveal location lugs and slots in the pallet configured to cooperate with the lugs.

FIGS. 22 and 23 are a top perspective and front orthogonal view, respectively, of the embodiment of FIG. 20, depicting a core-wound roll being supported on the present pallet system.

FIG. 24 is a side orthogonal view of the embodiment of FIG. 20, depicting a closed channel where the slide bar is disposed such that it engages two sides of the channel.

FIG. 25 is a side orthogonal view of the embodiment of FIG. 20, depicting an opened channel where the slide bar is disposed such that it is fully retracted into one side of the two sides of the channel.

FIGS. 26 and 27 are a top perspective and bottom perspective view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20.

FIGS. 28 and 29 are a top orthogonal and bottom orthogonal view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20.

FIGS. 30 and 31 are a side orthogonal and front orthogonal view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20.

FIGS. 32 and 33 are a top perspective and bottom perspective view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20.

FIGS. 34 and 35 are a front orthogonal and side orthogonal view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20.

FIGS. 36 and 37 are a top orthogonal and bottom orthogonal view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20.

FIG. 38 is a partial perspective view of another embodiment of the handhold for the slide bar.

FIGS. 39 and 40 are a top right perspective and top left perspective view, respectively, of a third embodiment of the present pallet system featuring foldable end boards.

FIG. 41 is a bottom perspective view of the embodiment the present pallet system shown in FIG. 39.

FIG. 42 is a side orthogonal view of the embodiment of FIG. 39, depicting a deployed retainer lip for the spindle of a smaller core-wound roll.

FIG. 43 is a side orthogonal view of the embodiment of FIG. 39, depicting a deployed retainer lip for the spindle of a larger core-wound roll.

FIG. 43A is a partial close-up perspective view of a retracted retainer lip for the spindle of a smaller core-wound roll.

FIG. 44 is a top orthogonal view of the embodiment of FIG. 39.

FIG. 45 is a bottom orthogonal view of the embodiment of FIG. 39.

FIGS. 46 and 47 are a front orthogonal and rear orthogonal view, respectively, of the embodiment of FIG. 39.

FIG. 48 is a top perspective view of the embodiment of FIG. 39 with an end board limiter and tab supports on one longitudinal end of the pallet system removed to reveal a lock mechanism used in securing the end board in an upright position.

FIG. 49 is top perspective view of the embodiment of FIG. 48 with a retainer removed from one longitudinal end of the pallet system to reveal an open channel ready to receive one end of a core-wound roll.

FIG. 50 is a partial cross-sectional view of a mechanism enabling gliding of an end board with respect to the deck on which the end board is disposed, depicting a deployed hook.

FIG. 51 is a partial cross-sectional view of a mechanism enabling gliding of an end board with respect to the deck on which the end board is disposed, depicting a retracted hook.

FIG. 52 is a partial perspective view of a mechanism for locking an end board in place.

FIG. 53 is a top right perspective view of a third embodiment of the present pallet system featuring foldable end boards.

FIG. 54 is a bottom right perspective view of the embodiment of FIG. 53.

FIG. 55 is a partial close-up view of the removable cradle of FIG. 54, depicting the mechanisms by which the removable cradle is seated to an end board.

FIG. 56 is a top right perspective view of a fourth embodiment of the present pallet system featuring foldable end boards.

FIG. 57 is a partial close-up view of a tab support of the present pallet system.

FIG. 58 is a partial close-up view of a tab support of the present pallet system with the fastener removed to reveal the slot which enables an end support to be foldable and supported on the pallet or glide strip when erected.

FIG. 59 is a top right perspective view of the embodiment shown in FIG. 56 with the glide structures removed to reveal glide strips.

FIG. 60 is a top right partially transparent perspective view of the embodiment shown in FIG. 56 with the glide structures removed to reveal glide strips, depicting a core-wound roll supported at two ends with end plugs.

FIG. 61 is a partially transparent top perspective view of a fifth embodiment of the present pallet system featuring a pallet for supporting more than one roll.

PARTS LIST

• 2—pallet
• 4—end board
• 6—length of end board
• 8—width of end board
• 10—recessed portion of end board
• 12—left longitudinal side or edge
• 14—right longitudinal side or edge
• 16—system formed of end boards and pallet
• 18—top transverse side or edge
• 20—bottom transverse side or edge
• 22—non-slip tape strip
• 24—location lug
• 26—slot
• 28—pocket
• 30—slot
• 32—cutout
• 34—non-slip tape
• 36—rolled edge to form slot
• 38—non-slip tape
• 40—center core cutout
• 42—picture frame
• 44—pressure sensitive label
• 46—steel core support ring
• 48—end board face
• 50—pallet decking
• 52—side fork opening
• 54—distance between end boards
• 56—document pouch
• 58—transverse edge of pallet
• 60—height of location lug
• 62—length of recessed portion of end board
• 64—width of recessed portion of end board
• 66—release surface
• 68—inner diameter
• 70—strap pocket
• 72—fork pocket strip
• 74—fork opening or pocket
• 76—location where a bead of weld is run
• 78—depth of end board
• 80—fastener
• 82—interior edges of picture frame
• 84—tab support
• 86—tab
• 88—end board limiter
• 90—U-shaped rod or retaining bracket
• 92—open core support
• 94—slide bar
• 96—cutout for accommodating location lug
• 98—hinge
• 100—channel
• 102—pad
• 104—core-wound roll
• 106—spindle
• 108—strap
• 110—knob
• 112—ring
• 114—aperture
• 116—weld bump
• 118—strapping port
• 120—upper decking
• 122—width of open core support
• 124—width of opening of open core support
• 126—rib
• 128—core retainer
• 130—retainer lip for smaller diameter core
• 132—retainer lip for larger diameter core
• 134—hinge
• 136—glide strip
• 138—hook
• 140—pivot of hook
• 142—tip of hook
• 144—opening for insertion of tip of hook
• 146—direction in which hook is rotated about pivot 140 to unlock hook
• 148—direction in which hook is rotated about pivot 140 to lock hook
• 150—plate
• 152—direction in which end boards are folded for storage
• 154—cut in retainer to form teeth
• 156—side location tab
• 158—glide track
• 160—pin
• 162—spacer glide
• 164—distance between end boards
• 166—pivot
• 168—glide structure
• 170—inverted channel
• 172—removable cradle
• 174—tab
• 176—slit
• 178—aperture
• 180—guard rail
• 182—multi-roll pallet
• 184—loop for securing strap
• 186—end plug
• 188—knurl

Particular Advantages of the Invention

Laser cut steel components are welded into end boards and pallets of the interlocking and stackable pallet systems over which a powder coated finish is applied to provide a surface that may be cleaned and/or sterilized, and thus, is ideal for food and medical applications. The metal components are free of splinters that may cause injury to users and/or contaminate nearby food or medical equipment during use. The metal components are free of sharp edges that may cause injury or damage during use.

The present stackable pallet system features end boards that are hingedly connected to a pallet, thereby removing the need to store the end boards separately, locate the end boards for installation, install the end boards on pallets and remove the end boards for storage. The end boards are simply erected for use and folded into a compact format when the pallet system is no longer needed.

In one embodiment, the present stackable pallet system features end boards having core supports such that a core-wound roll may be simple “dropped” onto and be supported by the core supports. The core is snuggly secured using a removable retainer having a selectable lip.

The distance between end boards is adjustable, eliminating the need for providing pallets of different sizes to support cores of various widths. The stackable pallet system features a plurality of U-shaped rods, each disposed at one of a plurality of bottom corners of the pallet of the pallet system such that a pair of the plurality of U-shaped rods at each longitudinal end of the platform cooperate to encompass an open edge of an end board of a second pallet system when the pallet system is disposed atop the second pallet system. Such U-shaped rods remove the need for precise loading of a pallet system atop a second pallet system, simplifying the work of stacking of erected pallet systems.

The stackable pallet system features a plurality of U-shaped rods and a plurality of tabs. Each U-shaped rod is disposed at one of a plurality of bottom corners of the pallet of the pallet system such that the valley of each U-shaped rod protrudes laterally from the pallet to form a loop with the pallet. Each tab is disposed at one of a plurality of top corners of the pallet of the pallet system. Each loop is configured to engage a tab of a second pallet system when the pallet system is disposed atop a second pallet system, removing any guesswork and simplifying the work involved in stacking folded pallet systems.

The stackable pallet system features a plurality of pads disposed at one of the plurality of bottom corners of the pallet of the pallet system. In one embodiment, such pad comprises expanded metal to provide suitable friction surface to engage the open edge of an end board.

The stackable pallet system features a pair of end board limiters, each end board limiter is disposed adjacent an end board and configured to restrict the rotation of the end board to about 90 degrees with respect to the top surface of the pallet such that over-rotation of the end boards can be prevented and the end boards can be repeatably erected to favorable orientations.

The interlocking and stackable pallet systems feature recessed pockets on the open ends of the fork pockets for plastic strap placement. The recessed placement of the straps prevents the plastic strap from being pinched and broken, thereby minimizing any chance that the roll will slip from the pallet deck surface.

The interlocking and stackable pallet systems feature non-slip tape surfaces applied to the underside of the pallet decking. The non-slip tape provides a friction surface between the pallet and the metal forks of pallet moving equipment.

The interlocking and stackable pallet systems feature non-slip tape surfaces applied to the top side of the pallet decking. The non-slip tape provides a friction surface between the pallet and the metal end boards.

The interlocking pallet system features laser cut slots in the pallet decking. These slots have mini-notches along the longitudinal sides that align with corresponding lugs on the metal end boards top and bottom edges. These slots provides proper location for the metal end boards when stacking two or more of the same size interlocking pallets and function to retain the metal end boards from sliding on the pallet deck.

The interlocking and stackable pallet systems can be manufactured in any size with no tooling, allowing for easy customization to meet the needs of any roll. The elimination of tooling significantly reduced manufacturing costs and time for new configurations.

The metal end boards of the interlocking and stackable pallet systems feature recessed pockets located on the vertical edges for plastic strap placement horizontally around the roll ends. These pockets create a repeatable pattern for the proper placement of the strap and protect the strapping from breakage so the roll will be prevented from sliding off of the interlocking pallet.

The metal end boards of the interlocking pallet system feature two location lugs with corner columns welded into matched image pockets on the top and bottom edge surface of the end board. These location lugs are aligned with the slots located on the deck and underside of the fork pockets.

In the interlocking pallet system, 2-inch wide non-slip tape strips are located on the location lugs and inside of the matched image pockets, creating a friction surface for additional friction between the end boards and the interlocking pallet surface. The same 2-inch side non-slip tape strips extend onto the flat surfaces of the face but not into the area of the roll being suspended. These non-slip tape strips keep the metal end boards from slipping during stacking and banding for shipping.

The metal end boards of the interlocking and stackable pallet systems feature a release surface of about 7.5 inches×12.5 inches adhered to one or more faces which will allow for placement and clean removal of pressure sensitive labels. This release surface is recessed into the structural body of the metal end boards to protect it from abrasion. In one aspect, a document pouch is provided for loose paperwork. The document pouch is easily removed and replaced if damaged. The release surface allows for thousands of reuses while keeping the end boards free of debris (such as adhesive residue) from paperwork.

The metal end boards of the interlocking and stackable pallet systems feature notched corners to allow air circulation and reduce the potential for rusting inside of the welded panels.

The metal end boards of the interlocking pallet system features a picture frame edge that is easy to handle and readily allows for pickup by the operators during loading and unloading. The edges of the picture frame are rounded and eliminate the potential for personal injury and provide an advantage in ergonomics workstation engineering for productivity.

Detailed Description of a Preferred Embodiment

The term “about” is used herein to mean approximately, roughly, around, or in the region of. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” is used herein to modify a numerical value above and below the stated value by a variance of 20 percent up or down (higher or lower).

The term “pallet,” “platform,” and “pallet decking” are used interchangeably herein to indicate a supporting body to which end boards are secured.

The term “core” is used herein to mean (a) a spindle inserted through the center of a core-wound roll used in suspending the core-wound roll when the ends of the spindle are placed on supports; or (b) end plugs inserted through the center of a core-wound roll used in suspending the core-wound roll when the end plugs are placed on supports.

Several detailed embodiments of the present invention are disclosed herein. It should be understood, however, that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make and/or use the invention. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

FIG. 1 is a perspective view of a first embodiment of the present pallet system, depicting two stacked and assembled end board-interlocking pallet assemblies. As depicted, a wider roll is disposed on the lower pallet and a narrower roll on a second interlocking pallet is positioned on top of the lower end board-interlocking pallet assembly. FIG. 2 is a top perspective view of one of the stacked assemblies depicted in FIG. 1 without a roll. Referring to FIGS. 1 and 2, an interlocking pallet 2 mates with two end boards 4 to form a system for transporting large core-wound rolls 104 of material. Laser cut steel components are welded into end boards 4 and interlocking pallets 2 over which a powder coated finish is applied. The metal components are free of splinters that may cause injury to users and/or contaminate nearby food or medical equipment during use. Metal also provides a surface that may be cleaned and/or sterilized, and thus, is ideal for food and medical applications. The metal components are free of sharp edges that may cause injury or damage during use.

FIG. 3 is a perspective view of an end board 4. FIG. 4 is a front orthogonal view of an end board 4. FIG. 5 is a side orthogonal view of an end board 4. FIG. 6 is a bottom orthogonal view of an end board 4. In the embodiment depicted, the end boards 4 are substantially square, having a length 6 and width 8 of from about 34 to about 40 inches and a depth 78 of about 1 inch. The longitudinal sides 12, 14 (nominally left 12 and right 14 edges) are disposed vertically when the end boards 4 are mounted for use and the transverse sides 18, 20 (nominally top 18 and bottom 20 edges) are disposed horizontally when the end board 4 is mounted for use on the interlocking pallet 2. Recessed pockets 28 are formed in the surface of the longitudinal sides 12 and 14.

The metal end boards 4 are provided with two or more location lugs 24 with corner columns welded on the transverse edges 18, 20, that is, the top 18 and bottom 20 edge, surfaces of the end board 4. The location lugs 24 are preferably 0.75 inch high 60, assuring at least 0.5 inch of the lug will be disposed in the slots of the interlocking pallet when mounted. The location lugs 24 preferably have a square cross section. These location lugs 24 are aligned with slots 26 (see FIGS. 9, 10 and 19) provided on the pallet decking 50 and underside of the fork pockets 74 (FIG. 19).

The location lugs 24 include a square cross profile with four corner knurls (see parts 188 of FIG. 7). This shape provides for a self aligning interference fit. The four knurls provide a manufacturing advantage in that they reduce complex multistep manufacturing required for serrated interior surfaces of the slots to four or five drill holes or laser cutouts.

In the embodiment depicted, the metal end boards 4 provide recessed pockets 28 on the longitudinal edges 12, 14 for plastic strap placement horizontally around the roll ends. These pockets 28 provide a repeatable pattern for the optimal placement of the strap and protect the straps from breakage so the roll form will be prevented from sliding off of the interlocking pallet 2.

Non-slip tape strips 22 are preferably disposed on and/or adjacent to the location lugs 24 and inside and/or adjacent to the slots 26 on the interlocking pallet 2. Typically, these non-slip tape strips 22 will be two inch wide and will provide a friction surface between the end boards 4 and the interlocking pallet 2 surface. The same 2 inch side non-slip tape strips 22 extend onto the flat surfaces of the inner and outer faces of the end board 4 and away from the portions directly adjacent to where the roll is suspended. This obviates any friction between the end board and the roll of material itself. These non-slip tape strips 22 keep the metal end boards 4 from slipping during stacking and banding for shipping.

The metal end boards 4 feature a release surface 66 adhered to one or more faces which will allow for placement and clean removal of pressure sensitive labels 44 or document pouches 56. This release surface 66 is recessed into the structural body of the metal end boards 4 to protect it from abrasion. In the embodiment depicted, the outer face of the end board 4 is divided into four quarters each having a recessed portion 10 of about 7.5 inches wide 64×12.5 inches long 62. It is to be appreciated that at least one recessed portion 10 and release surface 66 is provided in each end board 4. The size may be varied to meet the specific needs of the user and any number may be incorporated without departing from the spirit of the invention. In one aspect, a document pouch 56 is provided for loose paperwork. The document pouch 56 is easily removed and replaced if damaged. The release surface 66 allows for thousands of reuses while keeping the end boards 4 free of debris (such as adhesive residue) from paperwork.

Preferably, the metal end boards 4 feature notches at each corner to allow air circulation and reduce the potential for rusting inside of the welded end board 4 panels. The metal end boards 4 feature a picture frame 42 edge (formed in part by the recessed portions 10) that is easy to handle and readily allows for pickup by the operators during loading and unloading. The interior corner edges 82 of the picture frame 42 are rounded and eliminate the potential for personal injury and provide an advantage in ergonomics workstation engineering for productivity. FIG. 8 is a rear face orthogonal view of an end board and shows the face 48 does not contain the picture frame 42 edge or recessed features 10.

There is provided a center core cutout 40, a through hole, in each end board 4. Preferably, the center core cutout 40 measuring about 6.07 inch inner diameter 68 such that it is configured to snugly receive a common conventional 6 inch outer diameter roll core (on which the film is rolled) used in the flexible films industry. It is to be appreciated that this is the most common size, however, that other sizes of core cutouts 40 can be provided without departing from the spirit of the invention. Preferably, each center core cutout 40 is fitted with a steel core support ring 46. It is also to be appreciated that a 34 to 40 inch end board 4 includes the most common sizes, however, that other sizes of end boards 4 can be provided without departing from the spirit of the invention.

The interlocking pallet 2 is similar in many aspects to a conventional flush or wing style pallet, however, with the novel features described below that provide advantages not presently known in the art and not amounting to mere obvious reconfigurations of known components. FIG. 9 is a top perspective view of an interlocking pallet. FIG. 10 is a top orthogonal view of an interlocking pallet. FIG. 11 is a bottom orthogonal view of an interlocking pallet.

Pallets, including the interlocking pallet 2, are generally rectangular in shape. FIG. 13 is a partial enlarged top orthogonal view of one corner of an interlocking pallet. In one aspect of the interlocking pallet 2 depicted in FIG. 13, the corners have been modified to eliminate the sharp edges that often cause workplace injury. The sharp corners of the rectangle are replaced by a rounded edge at the juncture of the transverse and longitudinal sides, or alternatively, to have a triangular cutout or void at this corner junction. In one aspect, the corners are filled with the hinged tab and welding provides the smoothness of the corner.

FIGS. 12, 14 and 15 are a partial enlarged top perspective, a front orthogonal and enlarged side orthogonal view, respectively, of one corner of an interlocking pallet. In these views, the rolled interior edge of the pallet decking is observed. This rolled edge eliminates sharp surfaces and provides structural strength to the decking. In FIG. 15, a bead of weld is run at 76.

The interlocking pallet 2 provides recessed strap pockets 70 on the open ends of the fork pockets 74 for plastic strap placement. The recessed placement of the straps prevents the plastic strap from being pinched and broken, thereby minimizing any chance that the roll will slip from the pallet decking 50 surface. In the embodiment depicted, four recessed strap pockets 70 are provided on each transverse edge 58. Two are provided about each fork pocket 74.

The interlocking pallet 2 provides both end fork pockets 74 and side fork openings 52 (most clearly visible in FIG. 16) to facilitate easy maneuvering in multiple directions with pallet moving equipment. There is provided a rolled edge 36 at the strap pocket 70 (most clearly visible in FIG. 18), minimizing friction, wear and tear on the straps. The rolled edge 36 also provides both structural integrity (strength) and a contoured surface that reduces damage and injury due to sharp pallet edges. The fork openings 74, 52 are located, sized and configured to receive the forks of pallet moving equipment. In one common application, the fork openings 74 are at least about 10.88 inches wide and about 3.74 inches deep. There may be one long opening at least about 27.73 inches long as depicted for the side fork openings 52 (most clearly visible in FIG. 16) or two individual openings spaced about 5.93 inches apart (inner distance).

Below the decking in the area of the fork pockets is a fork pocket strip 72 that provides structural strength and functions as an anti-tip mechanism. Its purpose is to prevent accidental tipping of the pallet 2 while being transported, lifted, stacked or otherwise handled in the normal course of transportation movement. This is important in the safe handling required for stacking of the same size pallets, and offers particular advantages when different widths of rolls are intermixed. The option for mixed roll widths is a unique feature and benefit of this design.

Preferably, the interlocking pallet 2 provides non-slip tape 38 (see FIG. 11) surfaces applied to the underside of the pallet decking 50. The non-slip tape 38 provides a friction surface between the pallet 2 and the metal forks of pallet moving equipment to reduce potential relative movements of such forks and the pallet decking 50.

Preferably, the interlocking pallet 2 provides non-slip tape 34 (see FIG. 10) surfaces adjacent to and running parallel with the slots 26 applied to the top side of the pallet decking 50. The non-slip tape 34 strips may be provided on the interior and/or exterior longitudinal edges of the slots 26 to provide a friction surface to prevent slippage, especially when the pallets 2 are stacked on top of one another (with end boards 4 removed) for return shipment to the manufacturer or shipper. Friction is created between the upper face of the pallet decking 50 and the underside of a pallet 2 stacked directly on top.

The interlocking pallet 2 features laser cut slots 26 in the pallet decking 50. These slots 26 have mini-notches or serrations along the longitudinal sides that align with corresponding location lugs 24 on the metal end boards 4 top 18 and bottom 20 edges. These slots 26 provides proper location for the metal end boards 4 when stacking two or more of the same size interlocking pallets 2 and function to retain the metal end boards 4 from sliding on the pallet decking 50. The end boards 4 may be adjustably mounted on the interlocking pallet 2 such that they are disposed a distance 54 (see FIG. 2) of from about 37.5 to about 62 inches apart.

FIG. 18 is a partial top perspective view and FIG. 19 is partial a side orthogonal view of a corner of an assembled end board and interlocking pallet. In these views, the interlocking lugs and slots that facilitate vertical stacking of multiple end boards are observed. The protruding lug 24 on the top of one end board is received in the slot along the bottom of an interlocking pallet, thus inhibiting horizontal movement of the end board with respect to the interlocking pallet. The rolled transverse edge of the pallet decking is also observed. In FIG. 19, one function of the tape strips adjacent to the protruding lugs on the top of the end board is demonstrated. The tape strips provide a friction surface to prevent slippage of the interlocking pallet when pallet-end board assemblies are vertically stacked.

FIGS. 1-19 disclose a pallet system whose end boards are removable to be foldable. There is further provided a stackable pallet system in which the end boards are foldable but remain attached as shown in the ensuing figures. The basic features and construction practices of the pallet 2 and end boards 4 are largely identical to those of the interlocking pallet systems, except for the features to be pointed out in the ensuing description. Each ensuing embodiment of the present pallet system may include one or more features that are not available in one or more other embodiments. However, any feature is capable of being included in any embodiment although it is not shown is every embodiment. FIGS. 20 and 21 are a top perspective and bottom perspective view, respectively, of a second embodiment the stackable pallet system according to the present invention, featuring open core supports 92 and foldable end boards 4.

The pallet 2 includes a platform having a length, a width, a top surface, a plurality of top corners, a plurality of bottom corners and two longitudinal ends. Each end board 4 includes a substantially rectangular frame having a hinge edge, an open edge, an open core support 92 and a channel 100. Each end board 4 is hingedly connected at the hinge edge to one longitudinal end of the pallet 2 on the platform using a hinge 98. This removes the need to store the end boards 4 separately, locate the end boards 4 for installation, install the end boards 4 on pallets 2 and remove the end boards 4 for storage.

As end boards may be manufactured to suit pallets of various dimensions, the use of hingedly connected end boards removes guesswork associated with selecting the correct end boards for the pallets while enabling the pallet systems to be foldable for space savings. The open core support 92 is centrally disposed on the substantially rectangular frame and the channel 100 connects the open core support 92 to the free edge. The hinge 98 can be a continuous/piano hinge or a plurality of leaf hinges suitably spaced over the entire span of hinging operation of an end board with respect to a pallet, etc. In preparing the pallet system 16 for use, the end boards are simply erected to the positions shown in FIG. 20. A pair of end board limiters 88 is further provided. Each end board limiter 88 is essentially a plate that is disposed at substantially right angle to a top surface of the pallet 2 and adjacent an end board 4. It is configured to restrict the rotation of each end board 4 to about 90 degrees with respect to the top surface of the pallet 2 such that over-rotation of the end boards can be prevented and the end boards 4 can be repeatably erected to favorable orientations. There is further provided a plurality of pads 102, each disposed at bottom corner of the pallet 2. In one embodiment, such pad includes expanded metal to provide suitable friction surface to engage the open edge of an end board 4 of a second pallet system upon which the pallet system is disposed. In one embodiment, weld bumps 116 are provided on the corners of the top edge of an end board to interface with pads 102 on one longitudinal end of a second pallet 2 disposed above the present pallet 2.

The end boards 4 feature open core supports 92 to enable simple loading of a pallet system with a core-wound roll. The system 16 further includes a plurality of U-shaped rods 90 and a plurality of tabs 86. Each U-shaped rod 90 is disposed at a bottom corner of a pallet such that the valley of each U-shaped rod 90 protrudes laterally from the pallet to form a loop with the pallet. Each tab 86 is disposed at a top corner of the pallet. Each loop is configured to engage a tab 86 of a second pallet system when the pallet system is disposed atop a second pallet system, removing any guesswork and simplifying the work involved in stacking folded pallet systems. Each tab 86 represents an extension of a tab support 84 which is secured to a top surface of the pallet 2. In a preferred embodiment, each tab support 84 is a part of a larger bent bracket where a portion of the bracket is secured onto a pallet decking 50.

FIGS. 21A and 21B are a partial top perspective view of two folded and erected pallet systems, respectively, with the end board limiter 88 removed to reveal location lugs 24 of an end board 4 and slots 26 in the pallet 2 configured to cooperate with the lugs 24. While the end boards 4 are disposed in their folded position, the lugs 24 are disposed outside of the slots 26 but inside the cutouts 96. When erecting an end board 4, lugs 24 are rotated such that they enter the slots 26 preventing any lateral movements, alleviating any lateral load born by the hinge 98.

FIGS. 22 and 23 are a top perspective and front orthogonal view, respectively, of the embodiment of FIG. 20, depicting a core-wound roll 104 being supported on the present pallet system. Each roll 104 typically contains a core 106 in the form of a spindle of a certain diameter. Each longitudinal end of the spindle is configured to slide through each channel 100 to be seated on each open core support 92. It shall be noted that such configuration allows a simple “drop in” of the spindle 106 which is supported on the open core supports 92. In loading a core-wound roll, an operator simply lifts the roll 104 using a lifting device and lowers the roll 104 into the space bounded by the end boards 4. Upon loading of the pallet system, straps 108 may then be wrapped around the end boards 4 at recessed pockets 28 to further secure the pallet system.

FIG. 24 is a side orthogonal view of the embodiment of FIG. 20, depicting a closed channel 100 where the slide bar 94 is disposed such that it engages two sides of the channel 100. FIG. 25 is a side orthogonal view of the embodiment of FIG. 20, depicting an opened channel 100 where the slide bar 94 is disposed such that it is fully retracted into one of the two sides of the channel 100. The slide bar 94 is configured to be erected across each of the channels 100 to provide structural strength to each end board 4. The slide bar 94 serves a secondary purpose to prevent accidental dislodgement of the spindle 106 from each of the open core supports 92, although unlikely. The slide bar 94 is essentially a bar that rides in a cavity disposed along the open edge of an end board 4. A knob 110 is attached to the slide bar 94 to provide a handhold such that the slide bar 94 can be moved to the desired position manually.

FIGS. 26 and 27 are a top perspective and bottom perspective view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20. FIGS. 28 and 29 are a top orthogonal and bottom orthogonal view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20. FIGS. 30 and 31 are a side orthogonal and front orthogonal view, respectively, of two stacked erected pallet systems according to the embodiment of FIG. 20. When each pair of end boards 4 is erected, they are disposed substantially perpendicularly to the top surface of the pallet 2. Such stacking saves space and allows for more pallet systems to be fit into a unit volume of cargo space.

The pallet systems 16 are shown without core-wound rolls to more clearly depict the interfaces between the two stacked pallet systems 16. It shall be apparent, upon viewing these figures that on one bottom edge of the pallet 2, two U-shaped rods 90 of the top pallet system cooperate to encompass an open edge of an end board 4 of the bottom pallet system, preventing the top pallet system from sliding off the bottom pallet system while allowing imprecise stacking which saves time and labor costs in stacking the pallet systems and eliminates damages due to accidents in executing overly precise peg-hole type stacking.

FIGS. 32 and 33 are a top perspective and bottom perspective view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20. FIGS. 34 and 35 are a front orthogonal and side orthogonal view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20. FIGS. 36 and 37 are a top orthogonal and bottom orthogonal view, respectively, of two stacked folded pallet systems according to the embodiment of FIG. 20. When the pair of end boards 4 is folded, each end board 4 is disposed substantially coplanar to the top surface of the platform. Such stacking also saves space and allows for more pallet systems to be fit into a unit volume of cargo space, especially in a return trip after core-wound rolls have been delivered. In shall be noted that, while folded, the weight of a pallet system is placed on the tab supports 84 of the pallet system disposed below it, thereby preventing placement of excessive loads on the parts not designed to receive loads in the position in which they are disposed in the folded format, such as the end boards 4, etc. FIG. 38 is a partial perspective view of another embodiment of the handhold for the slide bar 94. In this embodiment, a ring 112 is disposed loosely through a pair of apertures 114 on the slide bar 94 such that a user can put a finger through the ring 112 to pull on the slide bar 94 or the ring 112 can be folded such that it is close to the slide bar 94 and out of the way of the space between the two end boards 4.

The interlocking pallet system and stackable pallet system can be manufactured in any size with no tooling, allowing for easy customization to meet the needs of any roll. The elimination of tooling significantly reduced manufacturing costs and time for new configurations. In the embodiments depicted, the pallets 2 are of conventional size of 61 inches long by 34 inches wide.

While 14 gauge metal is conventionally used for industrial applications, the structural design of the pallet 2 and end boards 4 allows lighter 16 gauge metal to be used. A plurality of weight reducing cutouts 32 (punched in the steel) may also be provided in the pallet 2 where the weight or materials costs are desirably decreased.

The utilization of computer aided design and the related use of computer driven lasers in combination effectively provides a methodology of component manufacturing that assures repeatability. The use of small detail cuts, tabs or otherwise intersecting parts are incorporated in the laser cutting of the flat components. The accuracy of the cuts in relationship to each other and as they relate to the final product assures the total functional use of the intention of the designed invention. This puzzle assembly is and may be used on all components of the pallet, end board or other materials as they may relate to the invention. This process is best depicted in FIGS. 12, 14, 15, 18 and 19.

Components are cut in flat format with the required shaping, bending and otherwise forming done without tooling. The formed components are aligned by the nicks, slots and related openings that have been specifically designed into the layout. The technique of interlocking parts creates an immediate increase in structural integrity. The properly aligned parts become square and true to the designed configuration allowing for high repeatability of welding. The puzzle assembly process benefits the welding on automated robotic welders or manual processes. The present pallet system may be constructed from durable materials, e.g., steel, aluminum, plastic with conventional manufacturing/molding techniques or fused deposition modeling/selective laser sintering techniques, commonly known as 3D printing or additive manufacturing.

FIGS. 39 and 40 are a top right perspective and top left perspective view, respectively, of a third embodiment of the present pallet system featuring foldable end boards. Upon removal of retainer 128 from an end board 4, a channel having a gradually enlarging opening from the core support to the opening of the channel is provided. The width of core support 122 is therefore less than the width of the opening of the core support 124. The enlarged opening makes loading of a core-wound roll easier using overhead cranes and reduces the number of pinch points while doing so as compared to a channel having a consistent width. Upon loading the pallet system with a core-wound roll, the retainer 128 of each end board is reinstalled, again preventing relative movements of the core-wound roll relative to the pallet. The substantially closed end boards also facilitate the use of automated storage systems as bar code or other identification labels may be applied to such end boards. The retainer 128 is essentially a T-shaped structure having an inverted channel 170 disposed atop a plate, which when mated to the end board 4, encases the top edge of the end board, thereby bridging the channel opening, stiffening the two portions of the end board 4 flanking the channel and preventing or reducing torsional deflections in the two portions. When deployed, the retainer 128 is substantially coplanar with the end board 4, thereby having no parts which project into the end of a core support on the pallet. FIGS. 39, 40, 41, 44, 45, 46, 47, 48, 49, 53 and 54 are shown with an extra retainer 128 disposed in its stowed position (on the upper decking 120) to depict the configuration in which a retainer can be stowed when not in use.

Each end board 4 is stiffened using a plurality of ribs 126. An end board 4 is essentially constructed from a frame strengthened with a plate 150 and ribs 126 disposed in a cross fashion on the plate. In one embodiment, the plate is a polymeric foam panel mounted on the frame with automotive style “Christmas tree” fasteners. An alternative to such end board requires significantly more materials, e.g., solid frame or filled-in frame. In order to further secure a retainer during transport, the retainer 128 is removed from its end board and disposed on the deck as shown in FIG. 40. Side location tabs 156 which project upwardly from the deck are used to retain the retainer on the deck by preventing the retainer from sliding off the deck.

A glide strip 136 (see FIGS. 48, 50 and 51), preferably made of a polymeric material, is used to support an end board 4, especially an end board 4 under load. As the glide strip 136 is capable of substantial deformation under load, deflections in the end board 4 are lessened. The glide strip 136 further lessens the friction between the end board 4 and the pallet decking 50. The distance between the two end boards 4 is adjustable. Each of the two end boards 4 is capable of adjustment along a pair of glide tracks 158 on each end of the pallet by means of a glide structure 168. In another embodiment not shown, only one glide structure is provided. In this embodiment, only one of the two end boards is made adjustable such that the distance between erected end boards is still adjustable by adjusting one of the end boards. Such embodiment requires only one glide structure, reducing the number of parts required for the present pallet system. Such embodiment however can result in a pallet that is not symmetrically loaded, especially when severe adjustment of the glide structure 168 is needed to accommodate a core-wound roll with a small width.

FIG. 41 is a bottom perspective view of the embodiment the present pallet system shown in FIG. 39. It shall be noted that the mechanisms for enabling stacking of pallet systems, i.e., the U-shaped rods 90 and pads 102 are essentially the same as those previously disclosed.

FIG. 42 is a side orthogonal view of the embodiment of FIG. 39, depicting a deployed retainer lip for the smaller spindle for a core-wound roll. FIG. 43 is a side orthogonal view of the embodiment of FIG. 39, depicting a deployed retainer lip for a larger spindle for a core-wound roll. FIG. 43A is a partial close-up perspective view of a retracted retainer lip for a smaller core-wound roll. Adjustable core retainer 128 on the center of an end board 4 is provided to contain the spindle of a core-wound roll from vertical movement as core-wound rolls come in different sizes, i.e., about 6 inches and about 8 inches outside diameter. The retainer 128 includes two retainers lips, with a first lip 132 used for containing the spindle of a smaller core-wound roll and a second lip 130 for containing a larger core-wound roll. The first lip 132 is essentially a plate having an edge configured in a semi-circular fashion such that this edge partially encircles the cross-sectional profile of the spindle of a core-wound roll to be supported. The second lip is essentially a plate having an edge configured in a semi-circular fashion such that this edge also partially encircles the cross-sectional profile of a core-wound roll to be supported. The plate is however hingedly connected to the retainer 128 via a hinge 134. In deploying the second lip 130, the second lip 130 is rotated in a first direction about the hinge 134 until its semi-circular edge is pointing in substantially the same direction as the semi-circular edge of the first lip 132 and obscuring the first lip 132. In retracting the second lip 130, the second lip 130 is rotated in an opposing direction to the first direction about the hinge 134 until its semi-circular edge is pointing in substantially the opposite direction as the semi-circular edge of the first lip 132. When two pallets are stacked, the cuts or teeth 154 disposed on each corner of the open edge of an end board 4 of the bottom pallet come in contact with a pad 102 of the top pallet system, affording friction which aids in preventing relative movements between the two pallets.

FIGS. 44 and 45 are a top orthogonal view and bottom orthogonal view, respectively, of the embodiment of FIG. 39. FIGS. 46 and 47 are a front orthogonal and a rear orthogonal view, respectively, of the embodiment of FIG. 39. As strapping ports 118 with rounded edges are located on the upper decking, the need to thread straps 108 under the deck via the fork truck openings is eliminated, thereby reducing the amount of labor and time required in securing the materials to be transported on the pallet. In one embodiment, each tab support 84 is an extension of a glide structure 168. The glide structure 168 is configured to be adjustable with respect to the pallet decking 50, along the direction delineated by the glide tracks 158 disposed the pallet decking 50. As each end board 4 is rotatably attached to a glide structure 168, the distance 164 between two erected end boards can be modified. Each end board 4 may be folded in direction 152 upon the upper decking 120 of a pallet to result in a compact package for stowage. FIG. 48 is a top perspective view of the embodiment of FIG. 39 with an end board limiter and tab supports on one longitudinal end of the pallet system removed to reveal a lock mechanism used in securing the end board 4 in an upright position. FIG. 49 is top perspective view of the embodiment of FIG. 48 with a retainer removed from one longitudinal end of the pallet system to reveal an open channel ready to receive one end of the spindle of a core-wound roll. FIG. 50 is a partial cross-sectional view of a mechanism enabling gliding of an end board 4 with respect to the decking on which the end board 4 is disposed, depicting a deployed hook. FIG. 51 is a partial cross-sectional view of a mechanism enabling gliding of an end board 4 with respect to the decking on which the end board 4 is disposed, depicting a retracted hook. A glide structure 168 including a pair of tab supports 84 supports an end board 4 at pivots 166, each on one lower side end of the end board 4. An end board 4 is therefore rotatably mounted on a glide structure 168. A locking mechanism is provided to ensure that the end board 4 stays erected. The locking mechanism includes a hook 138 pivotably mounted on the end board 4 at pivot 140. The hook 138 is essentially a bar which includes a handle on one end and a tip 142 on the opposing end and configured such that an actuation of the handle in direction 148 causes the tip 142 to be inserted in an opening 144 in a tab support 84, thereby preventing the end board 4 from rotating about pivot 166. In order to unlock the end board 4, the hook 138 is simply rotated in direction 146 until the tip 142 clears the opening 144. In order to enable movement of a glide structure 168 with respect to the upper decking 120, a pair of pins 160 are extended downwardly from the glide structure 168, each through a glide track 158 and secured with a spacer glide 162. A spacer glide 162 is disposed on the lower end of the glide track 158 to enable easier glide movements of the end board 4 atop the upper decking 120.

FIG. 52 is a partial perspective view of a mechanism for locking an end board in place. In this embodiment, the hook 138 is not mated with an opening in a tab support 84, but instead the tip 142 of a deployed hook presents a barrier for the end board 4 to rotate about pivot 166, thereby also maintaining the end board 4 in an upright position when erected.

FIG. 53 is a top right perspective view of a third embodiment of the present pallet system featuring foldable end boards 4. FIG. 54 is a bottom right perspective view of the embodiment of FIG. 53. FIG. 55 is a partial close-up view of the removable cradle of FIG. 54, depicting the mechanisms by which the removable cradle 172 is seated to an end board. In this embodiment, the open core support of a roll is made removable. A removable cradle 172 is provided for each end board 4. Each removable cradle 172 is essentially a curvilinear portion having two ends and a central portion where each end is terminated with a tab 174 and a third tab 174 is disposed at the central portion protruding outwardly from the central portion. Slits 176 are disposed at appropriate locations of each end board 4 for receiving the tabs 174 of a removable cradle 172. The shape of the removable cradle 172 is configured such that the removable cradle 172 fits snuggly in the end board. An aperture 178 is disposed in the tab 174 of the central portion of the removable cradle 172 and adapted to receive a lock, e.g., pin, to prevent accidental dislodgement of the removable cradle 172 from the end board. Another feature disclosed in this embodiment that is applicable to other embodiments is a guard rail 180 disposed on each side of an end board 4 as shown in FIG. 53. These guard rails 180 provide protection to a mounted roll as they protrude laterally to increase the size of the envelope within which the roll is disposed.

FIG. 56 is a top right perspective view of a fourth embodiment of the present pallet system featuring foldable end boards. FIG. 56 is shown without a core-wound roll already loaded. Loops 184 for securing straps 108 are provided on each end board 4 and core retainer 128 surfaces facing away from the pallet system. In this example, a loop 184 is disposed substantially centrally on the surface of the core retainer 128 facing away from the pallet system while another loop 184 is disposed at a portion of the end board below that of the loop 184 disposed on the core retainer at its mounted position. Loops 184 are disposed on core retainers 128 to ensure that when straps are disposed through these loops, the core retainers 128 are secured if they become detached due to accidental poor securement of these parts to the end boards 4. As a loop 184 is centrally disposed horizontally while secured to an end board 4, only one loop 184 is required, compared to possibly disposing at least two loops, one on each side of the present loop 184 of a core retainer 128. Strapping ports 118 are provided on the top surfaces of pallet decking 50 to allow strapping of the pallet system via portions of the pallet system that are easily accessible. As strapping ports 118 are disposed along the length of pallet on pallet decking 50, suitable routing of straps 108 through these ports 118 can be easily found to provide the neatest strapping solution possible.

FIG. 57 is a partial close-up view of a tab support 84 of the present pallet system. FIG. 58 is a partial close-up view of a tab support 84 of the present pallet system with the fastener 80, e.g., screw, removed to reveal the slot 30 of the tab support 84 through which the fastener 80 is inserted and tightened against a lower portion of the end board 4. An opening 144 is provided in the tab support 84 such that the tip 142 of the hook 138 is capable of being inserted and seated, retaining the end board 4 in its upright position. Upon removal of the tip 142 from opening 144, the end board 4 is no longer locked in place, allowing the end board 4 to be pivotably rotatable about slot 30. In the embodiment shown, the slot 30 is elongated and aligned at an incline with the bottom end of the slot 30 disposed closer to an end board limiter 88 than the top end of the slot 30. Such arrangement is used to ensure that there is sufficient play between the end board 4 and the tab support 84 such that the fastener engagement point (where the fastener is attached to the end board 4) can be slid upwardly along the path defined by the slot 30 when the end board 4 is rotated about the engagement point and when the end board 4 is erected, the end board 4 is capable of resting on glide strip 136 which is in turn disposed atop a decking 50 of the pallet. Each end board 4 is therefore supported on the entire contact surface between the bottom of the end board 4 and the glide strip 136, eliminating any pinch points, load concentration points and therefore mechanical failure that can occur due to any potential stresses exceeding that of material strength of the end board 4. A rigid end board 4 is unnecessary as the weight of a core-wound roll itself causes the roll to act as a cross bar to secure the two end boards 4 used to support it. The roll is further stabilized by straps 108 encompassing the two end boards 4 as shown in FIG. 56.

FIG. 59 is a top right perspective view of the embodiment shown in FIG. 56 with the glide structures 168 removed to reveal glide strips 136. As with the embodiment shown in FIG. 45, each of the two end boards 4 shown in FIG. 56 is capable of adjustment along a pair of glide tracks 158 on each end of the pallet by means of a glide structure 168.

FIG. 60 is a top right partially transparent perspective view of the embodiment shown in FIG. 56 with the glide structures removed to reveal glide strips, depicting a core-wound roll 104 supported at two ends with end plugs 186. It shall be noted that when installed as shown in FIG. 60, each core retainer 128 resists the tendency of its corresponding end plug 186 from tilting upwardly due to the weight of the core-wound roll the end plug 186 supports, thereby confining the end plug 186 to its core support.

FIG. 61 is a partially transparent top perspective view of yet another embodiment of the present pallet system featuring a pallet for supporting more than one roll. In this embodiment, rolls 104 are mounted laterally using end boards 4 having two open core supports 92 each. Two pallet systems may be ganged by combining two individual pallet systems at one of their long edges either permanently or removably. When combined removably, the two pallet systems may be jointed using fasteners, e.g., screws and nuts at the attached long edges. However, when intended to be combined permanently, permanent jointing techniques, e.g., welding, may be applied to the same long edges in addition to the fasteners or instead of the fasteners. By consolidating the two pallet systems into one, the combined pallet systems can be handled and transported as single unit, e.g., using fork lifts, etc., reducing the number of trips required of such equipment. Additional pallet systems may be added vertically as well provided that such addition does not exceed safe transport load limits.

The detailed description refers to the accompanying drawings that show, by way of illustration, specific aspects and embodiments in which the present disclosed embodiments may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice aspects of the present invention. Other embodiments may be utilized, and changes may be made without departing from the scope of the disclosed embodiments. The various embodiments can be combined with one or more other embodiments to form new embodiments. The detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, with the full scope of equivalents to which they may be entitled. It will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of embodiments of the present invention. It is to be understood that the above description is intended to be illustrative, and not restrictive, and that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Combinations of the above embodiments and other embodiments will be apparent to those of skill in the art upon studying the above description. The scope of the present disclosed embodiments includes any other applications in which embodiments of the above structures and fabrication methods are used. The scope of the embodiments should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. A stackable pallet system for storing and transporting a core-wound roll having a first core, said pallet system comprising:

(a) a pallet comprising a platform having a length, a width, a top surface, a bottom surface and two longitudinal ends;

(b) a pair of end boards, wherein each end board is pivotably connected to one of said two longitudinal ends of said platform such that when said pair of end boards are erected, said pair of end boards are disposed substantially in a parallel configuration, each of said pair of end boards is disposed at substantially right angle to said platform and when said pair of end boards are folded, said pair of end boards are disposed substantially parallel to the top surface of said platform; and

(c) a pair of core supports, wherein each of said pair of core supports is disposed on one of said pair of end boards, wherein each end of the first core is supported on one of said pair of core supports.

2. The stackable pallet system of claim 1, further comprising at least one glide structure configured to be glideable along at least one glide track disposed on said platform, said at least one glide structure is configured to be disposed on one of said two longitudinal ends, wherein at least one of said pair of end boards is pivotably connected to said at least one glide structure such that the distance between said pair of end boards is adjustable.

3. The stackable pallet system of claim 2, further comprising a glide strip disposed between said glide structure and said platform, wherein said glide strip is adapted to facilitate the gliding of said glide structure with respect to said platform.

4. The stackable pallet system of claim 1, wherein each of said pair of core supports comprises a removable cradle adapted to receive each end of the first core.

5. The stackable pallet system of claim 4, wherein said removable cradle is a curvilinear portion having two ends and a central portion, each end of said curvilinear portion is terminated with a tab and a third tab is disposed at the central portion protruding outwardly from the central portion and each of said pair of core supports comprises slits adapted to receive said tabs such that said removable cradle is removably attached to one of said pair of core supports.

6. The stackable pallet system of claim 1, wherein each of said pair of end boards further comprises:

(a) a hook rotatably mounted to each of said pair of end boards such that the plane of rotation of said hook is substantially parallel to the end board to which said hook is attached; and

(b) at least one opening disposed on a portion of said platform and configured for receiving a portion of said hook, wherein when said hook is disposed in a first rotational position, said portion of said hook is disposed within said opening, immobilizing the end board to which said hook is attached and when said hook is disposed away from said first rotational position, the rotation of the end board is not restricted.

7. The stackable pallet system of claim 1, wherein each said core support further comprises a core retainer capable of removable attachment to each of said pair of end boards, said core retainer is adapted to secure one end of the first core from a direction substantially opposite that of each said core support.

8. The stackable pallet system of claim 7, wherein said core retainer further comprises a retainer lip pivotably attached to a portion of said core retainer and said retainer lip is adapted to extend the reach of said retainer clip in a direction toward each said core support to accommodate a second spindle having a smaller diameter than the first core.

9. The stackable pallet system of claim 1, further comprising a plurality of retaining brackets, each retaining bracket disposed at a bottom corner of said platform such that when disposed atop a second stackable pallet system with erected end boards, two of said plurality of retaining brackets are disposed on one of said two longitudinal ends and cooperate to encompass an open edge of one of the pair of end boards of the second pallet system.

10. The stackable pallet system of claim 1, further comprising a plurality of tabs, each tab disposed at a top corner of said platform such that when disposed below a second stackable pallet system each of said plurality of tabs engages a retaining bracket disposed at a bottom corner of the second pallet system.

11. The stackable pallet system of claim 1, wherein each of said pair of end boards further comprises at least one recessed pocket disposed on at least one edge of each of said pair of end boards.

12. The stackable pallet system of claim 1, further comprising a pair of end board limiters, each end board limiter is disposed adjacent each said end board and configured to restrict rotation of each said end board to about 90 degrees with respect to the top surface of said platform.

13. The stackable pallet system of claim 1, further comprising a plurality of pads, wherein each of said plurality of pads is disposed at a bottom corner of said platform such that when disposed atop a second stackable pallet system with erected end boards, each of said plurality of pads provides friction surface to engage a corner of an open edge of an end board of the second stackable pallet system upon which the stackable pallet system is disposed.

14. The stackable pallet system of claim 1, further comprising a plurality of strapping ports disposed on said top surface of said platform to facilitate strapping of said stackable pallet system.

15. The stackable pallet system of claim 1, further comprising a plurality of teeth disposed on a portion of an open edge of each of said pair of end boards.

16. The stackable pallet system of claim 1, wherein said stackable pallet system is constructed from a material selected from the group consisting of steel, aluminum and plastic.

17. A stackable pallet system for storing and transporting a core-wound roll having a core, said pallet system comprising:

(a) a pallet comprising a platform having a length, a width, a top surface, a plurality of top corners, a plurality of bottom corners and two longitudinal ends; and

(b) a pair of end boards, each said end board comprises a frame having a hinge edge, an open edge, a core support, a channel and a retainer, wherein said each end board is pivotably connected to one longitudinal end of said platform, said core support is centrally disposed on said frame and said channel connects said core support to said free edge; and,

wherein when said pair of end boards is erected, each said end board is disposed substantially perpendicularly to said top surface of said platform, each longitudinal end of the core is configured to slide through each of said channels to be seated on each of said core supports and each of said retainers is configured to seal one of said channels to prevent dislodgement of the core from said core supports and when said pair of end boards is folded, each said end board is disposed substantially coplanar to said top surface of said platform.

18. The stackable pallet system of claim 17, further comprising a plurality of U-shaped rods, wherein each of said plurality of U-shaped rods is disposed at one of said plurality of bottom corners such that each pair of said plurality of U-shaped rods at each longitudinal end of said platform and each pair of said plurality of U-shaped rods disposed on one longitudinal end cooperate to encompass a second open edge of a second end board of a second pallet system when said pallet system is disposed atop the second pallet system.

19. The stackable pallet system of claim 17, further comprising a plurality of U-shaped rods and a plurality of tabs, wherein each of said plurality of U-shaped rods is disposed at one of said plurality of bottom corners such that the valley of each of said U-shaped rod protrudes laterally from said platform to form a loop with said platform, each of said plurality of tabs is disposed at one of said plurality of top corners and said loop is configured to engage a tab of a second pallet system when said pallet system is disposed atop the second pallet system with its end boards disposed in folded condition.

20. The stackable pallet system of claim 17, further comprising a glide structure at each longitudinal end of said pallet, wherein said glide structure is slidably connected to said top surface of said pallet, wherein one of said pair of end boards is pivotably connected to said glide structure.