SHIPPING PALLET AND/OR DECK USEFUL FOR SUCH

Abstract

A pallet 1 for carrying a load and be lifted by tines of a forklift is disclosed. The pallet 1 comprises a planar deck 10 for receiving a load thereon and a chassis below the deck for supporting the deck. The chassis comprises a plurality of hollow beams 112 of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support. The beams 112 span parallel to the plane of the deck 10 and each oriented with vertical sidewalls facing perpendicular to the plane of the deck 10 and horizontal sidewalls facing parallel to the plane of the deck 10. At each intersection of two beams of the grid a first of the two beams has both of its vertical sidewalls removed to allow a second of the two beams to pass through the first beam.

Description

FIELD OF THE INVENTION

The present invention relates to a shipping pallet and/or a deck useful for such.

BACKGROUND OF THE INVENTION

Shipping pallets for storing and transporting goods are primarily of a twin deck construction made from timber panels and beams. The top and bottom of the pallets are usually defined by wooden panels arranged in a parallel manner and that in concert act to provide the pallet as a laminate structure. This provides the pallet with high load bearing strength in bending and torsion. Being made from wood, such pallets are relatively cheap. They are usually designed to be able to receive the tines of a forklift to be lifted by the forklift when carrying a load.

However wooden shipping pallets have several disadvantages.

One disadvantage occurs in cross-border shipping of goods carried on such pallets. Being made from wood, regulations in some countries require the wood to be fumigated before being allowed to leave the seaport or airport of arrival and enter the country. This can be expensive and time consuming. If left untreated microbes may grow on/in the wooden pallets and this can be unhygienic.

Another disadvantage is that wooden pallets can absorb water and become heavy and weaker as a result. Wooden pallets are also very susceptible to impact damage. Leader board damage from forklifts driving too fast into the pallets is a common cause of failure.

Another disadvantage is that their transport, for return to origin for example, can be cost prohibitive and as such, the wooden pallets are often discarded after one use. The twin deck format of such a pallet does not lend itself to economic transport to origin due to the volume of space it consumes. Pallets able to nest in a stacked configuration solve this problem. U.S. Pat. Nos. 7,690,215 and 3,664,272 are examples. Nestable pallets such as this are typically single deck pallets. Twin decks usually prevent with nesting. But not having a twin deck “laminate” structure compromises the strength of such single deck pallets. Steel beams such as shown in U.S. Pat. No. 5,596,933 can be introduced to increase load bearing strength of a single deck pallet. If higher strength is desired, more/thicker steel beams can be added. Or the beams can be of a higher second moment of inertia to resist out of plane bending, this being best achieved by increasing the height of the beams. More/thicker steel beams increases the weight of the pallet which is undesirable because this adds to manufacturing and transport costs. Increasing the height of the beams reduces the compactness of stacked nested pallets which can increase storage and/or return shipping costs.

Pallets may be stored in storage racks that do not have a deck but instead two parallel pallet support rails. Typically, the pallets are supported on the two parallel rails of the storage rack, at two opposed edges of the pallets. Storage racks may come in two formats, the first being a drive thought format where pallets are loaded sequentially on two rails from one end of the rails and a second being standard racking where the pallets are loaded onto the rails lateral to the rail direction by being lowered onto the rails. The load on top of the pallet causes bending of the pallet between two rails. The pallet hence needs to be strong in bending to resist collapse under load. A single deck pallet whilst better suited for nested stacking with like pallets may be weaker in bending than a twin deck pallet of similar weight and size. In addition, standard rack loading and unloading of single deck pallets can be problematic. Tines of a forklift need a gap between the rails and the deck of the pallet.

When pallets are designed to have a chassis with plurality of beams in a grid formation, excessive welding may be required at least at each junction or intersection of the beams. Also, a chassis with excessive welding is not reliable and may not be too strong as there is a risk of cracks being formed at the welded portion or any other damage that can typically occur at the wielded portion especially due to fatigue or due to load or overload of the pallet. Even if the beams in a grid formation are non-metallic beams, excessive securement/bonding means (e.g. screws, nails, glues etc.) may be required at each junction or intersection of the beams. Cracks, breakage and/or other damages can typically occur to the securement/bonding means and/at the such portion of the chassis especially due to fatigue or due to load or overload of the pallet. The beam(s) can also accidently disengage from the rest of the pallet and/or fall due to fatigue or due to load or overload of the pallet.

OBJECT OF THE INVENTION

It is an object of the present invention to provide a shipping pallet that addresses at least some of the above-mentioned disadvantages and/or which will provide users with a useful choice.

STATEMENTS OF THE INVENTION

In a one aspect, there is provided a pallet for carrying a load and is able to be lifted by tines of a forklift, the pallet comprising a planar deck for receiving a load thereon and a chassis below the deck for supporting the deck, the chassis comprising a plurality of hollow beams orthogonal hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck,

wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.

In one embodiment, the beam with the sidewalls removed at the intersection has at least some of its bottom horizontal sidewall continuous over the intersection and parallel and preferably adjacent, and touches the bottom horizontal sidewall of the beam that passes through the first mentioned beam.

In one embodiment, the beam with the sidewalls removed at the intersection has at least some of its top horizontal sidewall continuous over the intersection and parallel and preferably adjacent, and touches the top horizontal sidewall of the beam that passes through the first mentioned beam.

In one embodiment, the beam that passes through the first mentioned beam has no cut-outs across of adjacent the intersection.

In one embodiment, the beam that passes through the first mentioned beam is of a constant cross section across and adjacent the intersection.

In one embodiment, the beam that passes through the first mentioned beam is welded to the first mentioned beam at regions where sidewalls of the two beams are adjacent each other.

In one embodiment, the beam that passes through the first mentioned beam is welded to the first mentioned beam at regions where sidewalls of the two beams are adjacent each other, other than at the bottom horizontal sidewalls.

In one embodiment, the beams are square or rectangular in cross section.

In one embodiment, the height of the beams defines substantially the thickness of the deck.

In one embodiment, at least one of the beams is made from a sheet metal.

In one embodiment, all said beams are made from a sheet metal.

In one embodiment, at least one beam is roll formed from a sheet metal.

In one embodiment, all said beams are roll formed from sheet metal.

In one embodiment, the sheet metal is no thicker than 1.8 mm thick.

In one embodiment, the sheet metal is about 1 mm thick.

In one embodiment, the pallet is square in shape.

In one embodiment, the pallet is rectangular in shape.

In one embodiment, the pallet is a shipping pallet.

In one embodiment, the grid is provided of at least two first set of said beams extending between a first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck.

In one embodiment, at least one of the first and second set of beams define a bottom portion of the deck at where the tines of the forklift is able to engage to lift the pal let.

In one embodiment, a bottom of at least one of the beams is provided with at least one of (a) an engineered profile (b) a double wall of said sheet material.

In one embodiment, the engineered profile and/or the double wall of said sheet material is provided in a manner to increase bend resistance at the bottom of the beam.

In one embodiment, the engineered profile and/or the double wall of said sheet material is provided in a manner to increase second moment of inertia at the bottom of the beam.

In one embodiment, the engineered profile of said sheet material is provided in a manner to increase bend resistance of the profile at the bottom of the beam.

In one embodiment, the engineered profile of said sheet material is provided in a manner to increase second moment of inertia of the profile at the bottom of the beam.

In one embodiment, the engineered profile of said sheet material is provided in a manner to increase second moment of inertia of the profile at the bottom of the beam.

In one embodiment, the first set of beams are of the same cross-sectional profile.

In one embodiment, the second set of beams are of the same cross-sectional profile.

In one embodiment, the first set of beams are at least 700 m long.

In one embodiment, the first set of beams are at least 800 m long.

In one embodiment, the first set of beams are at least 900 m long.

In one embodiment, the first set of beams are at least 1000 m long.

In one embodiment, the first set of beams are at least 1100 m long.

In one embodiment, the first set of beams are at least 1200 m long.

In one embodiment, the second set of beams are at least 700 m long.

In one embodiment, the second set of beams are at least 800 m long.

In one embodiment, the second set of beams are at least 900 m long.

In one embodiment, the second set of beams are at least 1000 m long.

In one embodiment, the second set of beams are at least 1100 m long.

In one embodiment, the second set of beams are at least 1200 m long.

In one embodiment, the first set of beams are no longer than 800 m long.

In one embodiment, the first set of beams are no longer than 900 m long.

In one embodiment, the first set of beams are no longer than 1000 m long.

In one embodiment, the first set of beams are no longer than 1100 m long.

In one embodiment, the first set of beams are no longer than 1200 m long.

In one embodiment, the second set of beams are no longer than 800 m long.

In one embodiment, the second set of beams are no longer than 900 m long.

In one embodiment, the second set of beams are no longer than 1000 m long.

In one embodiment, the second set of beams are no longer than 1100 m long.

In one embodiment, the second set of beams are no longer than 1200 m long.

In one embodiment, the beams of at least one of the first and second set of beams are quadrilateral in cross section and the engineered profile is a flange of said sheet metal extending into the interior or the beam.

In one embodiment, beams comprise of both a single ply of said sheet material wall construction and double ply of said sheet material wall construction.

In one embodiment, beams comprise of both a single ply of said sheet material wall construction and double ply of said sheet material wall construction at a lower region of the beam.

In one embodiment, a plurality of props extends downwardly from the deck to allow the pallet to be stably supported on a horizontal surface such as a ground, a deck or a similar or identical pallet.

In one embodiment, the props are formed (preferably integrally formed) as a part of a top panel for the deck.

In one embodiment, the pallet is able to be edge supported on parallel rails of a storage rack.

In one embodiment, the pallet is a single deck pallet.

In one embodiment, the pallet is able to nest with an identical pallet in a stacked condition.

In one embodiment, the pallet comprises four corners that are chamfered corners.

In one embodiment, a shock absorber is provided at each corner of the pallet.

In one embodiment, the shock absorbers are provided by rubber blocks.

In one embodiment, the deck of the pallet is rectangular and is 1200 mm in length and 1000 mm in breadth.

In one embodiment, total weight of the pallet is approximately 17 kg.

In one embodiment, total weight of the pallet is 30 kg or less, preferably 25 kg or less, preferably 23 kg or less.

In one embodiment, the beams are intermediate beams.

In one embodiment, at each grid or intersection of two beams, the welding occurs at the vertical sidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, the welding occurs only at the vertical sidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, the welding occurs at the vertical sidewalls and only one of the horizontal sidewalls of the beams.

In one embodiment, at each grid or intersection of two beams, no welding occurs at the horizontal sidewalls of the beams.

In one embodiment, each of the beams is spaced apart (or spaced) from each of the sides deck that is parallel to a longitudinal axis along which that beam extends.

In one embodiment, each corner of the chassis is secured with a corner bracket.

In one embodiment, each corner bracket is L-shaped.

In one embodiment, each corner bracket is secured with the chassis by welding.

In one embodiment, welding occurs at each (or at least one) intersection of two beams.

In one embodiment, at each (or at least one) intersection of two beams, welding occurs at only the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams, welding occurs at only the vertical sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams, welding occurs at both the horizontal and vertical sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams, welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) intersection of two beams, welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, welding occurs at the engineered profile of the beam or beams.

In one embodiment, welding occurs below the engineered profile of the beam or beams.

In one embodiment, welding occurs above the engineered profile of the beam or beams.

In one embodiment, welding occurs at each (or at least one) portion where two beams contact each other.

In one embodiment, at each (or at least one) portion where two beams contact each other, welding occurs at only the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beams contact each other, welding occurs at only the vertical sidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beams contact each other, welding occurs at both the horizontal and vertical sidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beams contact each other, welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, at each (or at least one) portion where two beams contact each other, welding occurs only at one of the horizontal sidewalls of the beams.

In one embodiment, the horizontal surface of at least one or each beam that is distal from the deck comprises a longitudinally extending slot extending between two ends of said at least one or each beam. In one embodiment, welding occurs in spaced apart configuration between along the longitudinally extending slot.

In another aspect, there is provided a pallet for carrying a load and is able to be lifted by tines of a forklift, the pallet comprising a planar deck for receiving the load thereon and a chassis below the deck for supporting the deck, the deck having a top portion for supporting the load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the chassis being in a grid formation and comprising a first set of at least two spaced apart and parallel beams extending between the first pair of opposed sides of the deck but spaced apart from the second pair of opposed sides of the deck, and a second set of at least two spaced and parallel beams extending between the second pair of opposed sides of the deck but spaced apart from the first pair of opposed sides of the deck,

wherein the first set of beams are orthogonal to the second set of beams,

wherein at each intersection of two beams of the grid a first of said two beam has a notch or a slot to allow a second beams to pass through the first beam.

In one embodiment, the beams are hollow beams of constant quadrilateral cross section, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck.

In one embodiment, the notch or the slot is formed by removing both the vertical sidewalls of the said first beam.

In one embodiment, the slot is formed by removing both of its vertical sidewalls removed and one of the horizontal sidewalls of said first beam, one of the horizontal sidewalls being proximal to the deck.

In one embodiment, the pallet and/or deck is of a kind as hereinbefore or hereinafter described.

In a further aspect, there is provided a single deck pallet comprising:

a deck having a top portion for supporting a load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the bottom portion comprising a chassis, the chassis comprising a plurality of orthogonal hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck,

wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.

In one embodiment, the grid formation is provided of at least two first set of said beams extending between the first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck.

In one embodiment, at least one of the first and second set of beams define a bottom portion of the deck at where the tines of the forklift is able to engage to lift the pal let.

In one embodiment, the pallet and/or deck is of a kind as hereinbefore or hereinafter described.

In a yet further aspect, there is provided a pallet as defined in any one of the above statements, wherein the pallet comprises a plurality of discretely distributed primary props dependent from the deck and projecting below a or the bottom portion of the deck to aid in supporting the pallet on a surface.

In one embodiment, the pallet is capable of being edge supported by spaced apart parallel rails of a storage rack.

In one embodiment, the pallet further comprises a plurality of discretely distributed primary props dependent from the deck and projecting below the bottom portion of the deck to support the pallet on a surface.

In one embodiment, the pallet further comprises a plurality of discrete secondary props for supporting the pallet on the rails of the storage rack, each secondary prop projecting below the bottom portion of the deck and being provided intermediate of a primary prop and an associated at least one of the four sides of the deck to elevate the bottom portion of the deck above the rack such as to accommodate the passage of a forklift tine between a rail of the rack and the deck of the pallet.

In one embodiment, both the primary props and secondary props are spaced apart so as to allow two tines of a forklift to pass between both the primary props and secondary props to come to bear on the bottom portion of the deck.

In one embodiment, width of the deck between the or a first pair of opposed sides of the deck is greater than a gap between the two spaced apart parallel rails of the storage rack upon which the pallet is able be supported on the secondary props.

In one embodiment, the plurality of primary props is spaced inwardly adjacent and along the first pair of opposed sides to allow the primary props to sit intermediate of the rails of a storage rack.

In one embodiment, the primary props provided along each of the first pair of opposed sides are spaced apart between the first pair of opposed sides such that said primary props may sit intermediate of the rails of a storage rack.

In one embodiment, the primary props are provided along each of the first pair of opposed sides are spaced apart so as to prevent either of the first pair of opposed sides from falling off the rails of the storage rack due to a lateral movement of the pallet relative to the rails when the pallet is supported on the rails by the secondary props.

In one embodiment, the primary props provided adjacent each of the first pair of opposed sides are spaced between the first pair of opposed sides such that, when the rack is supported on the rails by the secondary props, the primary props adjacent each of the first pair of opposed sides engage with the rails to substantially prevent movement of the pallet lateral of the rails.

In one embodiment, the primary props provided along each of the first pair of opposed sides comprise a lead-in such that each primary prop tapers away from the adjacent one of the first pair of opposed sides as the primary prop projects away from the base of the deck.

In one embodiment, the primary props each comprise a projection from the base of the deck, each projection at least in part tapering inwards from each of the first pair of opposed sides as the primary props extends from the base of the deck.

In one embodiment, the plurality of primary props is spaced adjacent and along the or a second pair of opposed sides, so as to allow the primary props to sit intermediate of each respective second side and the primary props adjacent each second side.

In one embodiment, the primary props provided along each of a or the second pair of opposed sides are spaced apart so as to prevent either of the second pair of opposed sides from falling off the rails of the storage rack due to a lateral movement of the pallet relative to the rails when the pallet is edge supported on the rails by portions of the deck proximate to each of the second pair of opposed sides.

In one embodiment, the primary props provided along each of the second pair of opposed sides comprise a lead-in such that the primary prop tapers away from the adjacent one of the second pair of opposed sides as the primary prop projects away from the base of the deck.

In one embodiment, a distance the primary props project away from the bottom of the deck is greater than a distance the secondary props project from the deck.

In one embodiment, the primary props provided adjacent each of the second pair of opposed sides are spaced between the second pair of opposed sides such that when the rack is edge supported on the rails, the primary props adjacent each of the second pair of sides engage with the rails to substantially prevent movement of the pallet lateral of the rails.

In one embodiment, the primary props provided along each of the second pair of opposed sides comprise a lead-in such that each primary prop tapers away from the adjacent one of the second pair of opposed sides as the primary prop projects away from the base of the deck.

In one embodiment, the primary props adjacent each of the first pair of opposed sides of the deck are inset from their associated side of the deck.

In one embodiment, the plurality of primary props is distributed in a grid format from the deck.

In one embodiment, the pallet comprises at least four primary props, wherein four of the at least four primary props are provided adjacent to and at one end of each of the two opposed sides.

In one embodiment, the deck comprises four corners at the intersection of the first pair of sides and second pair of sides, and four primary props are provided at or towards each of the four corners.

In one embodiment, the deck is or comprises a quadrilateral shape.

In one embodiment, the deck is or comprises a rectangular or square shape.

In one embodiment, the deck comprises one or more rounded or chamfered corners.

In one embodiment, the plurality of primary props is inset from each of the first pair of opposed sides.

In one embodiment, the plurality of primary props are spaced inwardly adjacent and along both the first pair of opposed sides and second pair of opposed sides.

In one embodiment, the secondary props are provided only intermediate of primary props located adjacent and along the first pair of opposed sides.

In one embodiment, the secondary props are not provided intermediate of primary props located adjacent and along the second pair of opposed sides.

In one embodiment, the number of secondary props correspond to the number of primary props provided directly adjacent each of the first pair of opposed sides of the deck.

In one embodiment, the pallet comprises at least four secondary props, wherein four of the at least four secondary props are associated with four primary props provided adjacent to and at an end of each of the first set of opposed sides.

In one embodiment, the width of the secondary props along the direction of the first set of opposed sides is less than the width of the primary props along the direction of the first set of opposed sides.

In one embodiment, at least some of the secondary props are dependent from the deck.

In one embodiment, at least some of the secondary props are dependent on at least some of the primary props.

In one embodiment, the secondary props are dependent from primary props located adjacent each of the first pair of opposed sides.

In one embodiment, the pallet may be supported on the rails of the rack on the plurality of secondary props, such that a forklift may access the pallet in a direction substantially perpendicular to the rails of the rack.

In one embodiment, the pallet may be supported on the second set of opposed sides of the deck, such that a forklift may access the pallet in a direction substantially parallel to the rails of the rack.

In one embodiment, the deck between the primary props and each side of the second pair of opposed sides comprises a ledge, such that a pallet supported on the second side of opposed sides is supported on the ledge of the deck.

In one embodiment, the deck comprises a top panel, and dependent from the top panel are the primary props.

In one embodiment, the primary props are integrally formed with the top panel of the deck.

In one embodiment, the top panel comprises a plurality of primary hollow depressions corresponding to the number of primary props and shaped to nest with the primary props of another pallet, preferably as hereinbefore or hereinafter described.

In one embodiment, the nesting comprises an at least partial receiving of the primary props of another pallet within the plurality of primary hollow depressions of the top panel.

In one embodiment, the top panel comprises a plurality of secondary hollow depressions corresponding to the number of secondary props and shaped to nest with the secondary props of another pallet, preferably another single deck pallet, preferably as hereinbefore or hereinafter described.

In one embodiment, the nesting comprises an at least partial receiving of the secondary props of another pallet within the plurality of secondary hollow depressions of the top panel.

In one embodiment, the primary depressions comprise one or more tertiary props projecting towards the deck of the pallet such that the deck of the pallet and the deck of a nested pallet remain separated so as to allow the tines of a forklift to pass between decks.

In another aspect, there is provided a system of a pallet rack and a pallet as hereinbefore or hereinafter described, wherein the pallet is a single deck pallet that is either

supported on the rails of the pallet rack on the plurality of secondary props, the opposed sides of the pallet being substantially parallel with the rails of the rack, or

supported on the opposed ends of the deck, the opposed ends of the pallet being substantially parallel with the rails of the rack.

In one embodiment, the pallet is of a kind as described above.

In yet another aspect, there is provided a plurality of pallets as hereinbefore or hereinafter described, the pallets being single deck pallets provided in a nested condition relative to each other.

In one embodiment, secondary props are provided along all sides of the deck.

In one embodiment, the spacing of parallel beams between two adjacent primary props in a first orthogonal direction is different to the spacing of parallel beams between two adjacent props in a second orthogonal direction.

In one embodiment, the spacing between beams and adjacent primary props is the same for beams between all adjacent props in said orthogonal direction.

Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.

For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawings and described in the following description are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

It is acknowledged that the term “comprise” may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term ‘comprise’ shall have an inclusive meaning, allowing for inclusion of not only the listed components or elements, but also other non-specified components or elements. The terms ‘comprises’ or ‘comprised’ or ‘comprising’ have a similar meaning when used in relation to the system or to one or more steps in a method or process.

As used hereinbefore and hereinafter, the term “and/or” means “and” or “or”, or both.

As used hereinbefore and hereinafter, “(s)” following a noun means the plural and/or singular forms of the noun.

When used in the claims and unless stated otherwise, the word ‘for’ is to be interpreted to mean only ‘suitable for’, and not for example, specifically ‘adapted’ or ‘configured’ for the purpose that is stated.

For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.

For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be chronologically ordered in that sequence, unless there is no other logical manner of interpreting the sequence.

The entire disclosures of all applications, patents and publications, cited above and below, if any, are hereby incorporated by reference.

For the purposes of this specification, the term “plastic” shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer. PLA is also envisaged.

For the purpose of this specification, where method steps are described in sequence, the sequence does not necessarily mean that the steps are to be chronologically ordered in that sequence, unless there is no other logical manner of interpreting the sequence.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which:

FIG. 1 shows a perspective view of a pallet of a preferred form of the present invention shown from above,

FIG. 2 is a bottom perspective view of the pallet of FIG. 1,

FIG. 3 is a top plan view of the pallet of FIG. 1,

FIG. 4 is a bottom plan view of the pallet of FIG. 1,

FIG. 5 is a side view of the pallet of FIG. 1,

FIG. 6 is an end view of the pallet of FIG. 1,

FIG. 7 shows two pallets nested in a stacked configuration in a cross-sectional view,

FIG. 8 shows a cross sectional perspective view of the pallet of FIG. 1,

FIG. 9A shows a pallet carrying goods stored in standard racking on parallel rails of the rack, seen in front view,

FIG. 9B is a view in direction AA of FIG. 9A,

FIG. 10A shows a pallet of a kind as shown in FIG. 1 shown on drive through racking, the pallet carrying goods,

FIG. 10B shows a view in direction BB of FIG. 10A,

FIG. 11A shows a side view of a variation of a pallet,

FIG. 11B shows a side view of a further variation of a pallet,

FIG. 11C shows a side view of yet a further variation of a pallet,

FIG. 12A shows an end view of a variation of a pallet,

FIG. 12B shows an end view of a variation of a pallet,

FIG. 12C shows an end view of a further variation of a pallet,

FIG. 13A shows a bottom view of a pallet according to an embodiment of the present invention having perimeter beams and props,

FIG. 13 B shows a bottom view of an embodiment of a pallet according to another embodiment of the present invention having a props but no perimeter beam,

FIG. 13 C shows a bottom view of a pallet according to yet another embodiment of the present invention having perimeter beams but no props,

FIG. 13 D shows a bottom view of an embodiment of a pallet having no props and no perimeter beam,

FIG. 13 E shows a tine of a forklift for lifting a pallet of FIG. 13A-FIG. 13D,

FIG. 14 shows a bottom perspective view of the pallet of FIG. 13A,

FIG. 15 shows a sectional perspective view of the pallet of FIG. 13D,

FIG. 15A is a side view of a deck of a pallet and a forklift tine,

FIG. 15B is a side view of a deck of a pallet end supported on rails showing deflection of the deck when under loading,

FIG. 15C is a side view of a deck of a pallet showing uneven loading and the resulting uneven curvature of the deck that may result from such loading,

FIG. 16 shows a top plan view of the metal framework of one example of a chassis of the deck for use in a pallet of the present invention,

FIG. 16A shows a detailed view of section A of FIG. 16,

FIG. 17 shows a bottom plan view of the chassis of FIG. 16,

FIG. 17A shows a detailed view of section B of FIG. 17,

FIG. 18A shows one example of a beam that may be used in or to define the chassis of the of the deck for use in a pallet of the present invention,

FIG. 18B shows a top plan view of the beam of FIG. 18A,

FIG. 18C shows a side view of the beam of FIG. 18A,

FIG. 18D shows another example of a beam that may be used to define the chassis of the deck for use in the pallet of the present invention,

FIG. 18E shows a side view of the beam of FIG. 18D,

FIG. 18F shows an end view of the beam of FIG. 18D. This is can also be considered as a cross sectional view of the beam of FIG. 18A or 18D in a plane that is orthogonal to the longitudinal axis of the beam at a location that does not comprise a notch or a slot,

FIGS. 19A to 19B are bottom partial perspective views showing two beams being coupled at the notch of one of the two beams at an intersection or grid,

FIG. 19C is a top perspective view of two beams showing the two beams being be coupled at the slot of one of the two beams at an intersection or grid,

FIG. 20A shows portions two beams at an intersection or grid where welding can occur,

FIG. 20B shows the horizontal wall of a beam being in tension when a load is applied to the beam,

FIG. 21A shows a bottom perspective view of the metal framework of one example of a chassis of the deck for use in a pallet of the present invention,

FIG. 21B is a bottom plan view of the chassis of FIG. 21A,

FIG. 21C shows a view in direction XX of the chassis of FIG. 21B,

FIG. 21D shows a view in direction YY of the chassis of FIG. 21B,

FIG. 21E is a top plan view of the chassis of FIG. 21A,

FIG. 22A shows a detailed view of section C of FIG. 21B,

FIG. 22B shows a detailed view of section D of FIG. 21B,

FIG. 22C shows a detailed view of section E of FIG. 21B,

FIG. 22D shows a detailed view of section F of FIG. 21B,

FIG. 22E shows a detailed view of section G of FIG. 21E,

FIG. 22F shows a detailed view of section H of FIG. 21E,

FIG. 22G shows a cross-sectional view along direction V-V of FIG. 21C,

FIG. 22H shows a cross-sectional view along direction ZZ of FIG. 21E,

FIG. 23A shows a perspective view of one of the beams of chassis of FIG. 21A,

FIG. 23B shows an end view of the beam of FIG. 23A,

FIG. 23C shows a top plan view of the beam of FIG. 23A,

FIG. 23D is a side view of the beam of FIG. 23A,

FIG. 24A shows a perspective view of another one of the beams of chassis of FIG. 21A,

FIG. 24B shows an end view of the beam of FIG. 24A,

FIG. 24C shows a top plan view of the beam of FIG. 24A,

FIG. 24D is a side view of the beam of FIG. 24A,

FIG. 25 shows a corner bracket of the chassis of FIG. 21A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

With reference to FIGS. 1 and 2 a single deck pallet 1 is shown. The single deck pallet 1 is capable of being edge supported by spaced apart parallel rails of a storage rack. It is also capable of being lifted by forklift tines. The single deck pallet 1 may comprise of a deck 10 (defining the plan shape) having a top 11 for supporting a load and a bottom 12. The preferred construction and materials used for the deck is described further below.

The deck 10 of the pallet 1 comprises at least 4 sides, which f includes the first pair of sides oppose sides 13 and second pair of opposed sides 14. The pallet can be edge supported along at least one pair of opposed sides of the deck. In most preferred forms the deck will be of a substantially quadrilateral shape such as a rectangle or square shape. Furthermore, the deck may correspond to standardised sizes of pallets commonly used in industry.

In a preferred form the pallet is of a square or rectangular plan shape and it may be of the following dimensions (with preferred total minimum load capacity in edge supporting mode shown) as examples:

• • 600×800 (2000 kg)
  • 1000×1200 (2000 kg)
  • 1000×1000 (2000 kg)
    Other deck sized may include:
  • 1000×1200
  • 1006×1206
  • 1016×1219
  • 1067×1067
  • 1200×1200
  • 1020×1200
  • 1060×1200
  • 1100×1100
  • 1165×1165
  • 1166×1242

In a preferred form, for example as shown in FIGS. 1 and 2, the majority of the perimeter of the deck is formed to define a first pair of opposed sides 13 and second pair of opposed sides 14. The first and second pairs of opposed sides intersect with each other at four corners of the deck 10. In some embodiments, the deck may comprise of one or more chamfered corners (see FIG. 1). In addition, or alternatively, the corners of the deck may also comprise impact absorbers such as rubberized covers (e.g. rubber blocks) or attachments for each of the corners.

The pallet may comprise of a plurality of discretely distributed primary props 15. A plurality of discretely distributed primary props 15 are shown in the view of FIG. 2. The plurality of primary props 15 are preferably dependent from the deck 10 and project below the bottom 12 of the deck 10 to support the pallet on a surface such as the ground or a storage rack deck in a manner to support the deck in an elevated manner above the ground/storage rack deck. This ground clearance allows forklift tines to pass under the deck and then lift the pallet at the deck (by bearing onto the bottom 12 of the deck 10). All primary props preferably project to an equal distance from the deck 10.

At least two primary props 15 are preferably located adjacent each edge of the deck 10 so as to provide a stable platform for goods carried on the deck when the pallet is supported on a ground or on another deck or any other horizontal or substantially horizontal surface. There may hence be at least 4 primary props, one adjacent each corner of the deck. Further props may be provided along each edge and/or intermediate of the edge located props.

Preferably the primary props 15 have openings at their base to allow for liquid to flow through. The deck 10 preferably has air-holes. Preferably the top panel or top surface is of one piece and may have an edge lip. It may be covered in an anti-slip coating.

As shown in FIGS. 1 and 2, the pallet 10 may further comprise of a plurality of discrete secondary props 16. In order to provide spacing such that two tines of a forklift may pass between both the primary props 15 and secondary props 16 and to come to bear on the bottom of the deck, the primary props may be distributed in a grid format from the deck. For example, one such grid format is shown in FIGS. 2 to 4, wherein nine primary props 15 project below the deck and are arranged into aligned rows and columns.

The primary props 15, and particularly the peripheral primary props, being those closest to a side or sides of the deck 10, may have purposive spatial relationships to either or both of the first pair of sides 13 and second pair of sides 14, as herein after described.

As shown in FIGS. 9A-9B and 10A-10B the secondary props 16 may, in certain conditions, be used for edge supporting the pallet 1 on the rails 19 of a rack 17 so as to elevate the deck 10 above the rails 19. Such elevation allows forklift tines to pass through the gap between the rails and the deck and then lift the pallet 1 by engaging the bottom of the deck 10. The racking system that may be used for accommodating a pallet in this configuration is sometimes known as standard racking.

Each secondary prop 16 preferably projects below the bottom 12 of the deck 10. They all preferably project to an equal distance from the deck 10.

In a preferred form secondary props 16 are located near the ends of an adjacent edge to help provide a stable platform for goods carried on the pallet 1 when edge supported on standard rack rails.

In a plan view, the secondary props 16 are preferably each provided intermediate of a primary prop 15 and an adjacent one of the four sides of the deck 10.

For example, as shown in FIGS. 1 and 2, a number of primary props 15 are provided adjacent and along each of the first pair of sides 13. Each of the secondary props 16 are then provided intermediate of each of these primary props 15 and their respective one of the first pair of sides 13. In other embodiments the secondary prop 16 may be provided in their intermediate configuration along either or both of the first pair of sides 13 and second pair of sides 14.

Shown in FIGS. 3 and 4 are views from above and below the pallet 1, showing the top 11 of the deck 10, the bottom 12 of the deck 10, and the primary props 15 and secondary props 16.

In a stored configuration when the secondary props 16 support the pallet 10 on the rails 19 of a rack 17, the secondary props serve to elevate the bottom 12 of the deck 10 above the rack 17 more specifically rails 19 of the rack 17. This elevation of the bottom of the deck 10 is to be at least such as to accommodate the passage of a forklift tine between a rail 19 of the rack 17 and the deck 10 of the pallet 1.

Shown in FIG. 5 is a side view of the pallet 1. The secondary props 16 are shown in their preferred position intermediate of the outer primary props 15 and the first pair of sides 13. In some forms of pallet (not shown), secondary props 16 are also provided along each of the secondary pair of sides 14. However, in the preferred form, secondary props 16 are not provided along each of the secondary pair of sides 14. Instead, a ledge 20 of the bottom 12 of the deck 10 is provided between the primary props 15 and each of the second sides 14. This is shown for example in FIG. 10b and is so provided to make the pallet suitable for drive-through racking as will hereinafter be described.

As seen in FIGS. 1 and 2, both the primary props 15 and secondary props 16 are horizontally spaced apart so as to allow two tines 100 of a forklift spaced at distance D apart, to pass between both primary props 15 and secondary props 16 to come to bear on the bottom 12 of the deck 10. This spacing apart of the primary props and secondary props may be a spacing in either the direction of the length of the first pair of sides 13 or second pair of sides 14. In a preferred form however this horizontal spacing of the primary props and secondary props is in both the direction of the first pair of sides 13 and the second pair of sides 14 so that the pallet can be used as a 4-way pallet. In such a configuration, two tines of a forklift may be allowed to pass between both the primary props and the secondary props and come to bear on the bottom of the deck when the tines of the forklift are introduced in a direction substantially perpendicular to either of the first pair of sides 13, or to either of the second pair of sides 14.

In order to accommodate the secondary props 16, the primary props 15 may be inset from each of the first pair of sides 13. This is particularly in the configuration seen in FIGS. 1 and 2, where the secondary props 16 are positioned intermediate of the primary props 15 and one of the first pair of sides 13, but also directly between each primary prop 15 and its adjacent portion of its associated one of the first pair of sides 13.

In some forms the secondary props 16 may be provided at different positions along the first pair of sides 13, such that they are not directly between a primary prop 15 and an adjacent portion of one of the first pair of sides 13.

In some embodiments the secondary props 16 may extend right up to their respective ones of the first pair of sides 13.

The secondary props 16 may be provided as dependent from either or both of the deck 10 and the primary props 15. Three example configurations of the secondary props 16 are shown in FIGS. 11A to 11C. In FIG. 11A, the secondary props 16 are dependent from, and potentially integrally formed with, both of the deck 10 and primary props 15. In FIG. 11B, the secondary props 16 are provided as dependent only from their associated primary props 15. In FIG. 11C, the peripheral secondary props 16 are also to be provided in a specific relationship in relation to the second pair of sides 14. The secondary props 16 are preferably at least partially nestable but may not be nestable.

The pallet 1 may be edge supported on the rails of a storage rack. A preferred form of providing such edge support is by providing the primary props 15 located along each of the second pair of sides 14 inset from their respective one of the second pair of sides in order to provide a ledge 20. A view of a pallet 1 along the second pair of sides 14 and showing the ledge 20 upon which the pallet may be edge supported is shown in FIG. 10b. If the secondary props 16 are not provided in a corresponding location along the first pair of sides 13 to the primary props 15 then the secondary props 16 at either end of the first pair of sides 13 may also need to be inset from the second pair of sides 14 in order to provide the ledge 20 for this format of rack support.

In the preferred form the ledge 20 adjacent each second pair of sides 14 allows the pallet to be edge supported along the length of the second pair of sides on a pair of rails 19.

In a preferred embodiment the primary props 15 are inset from both of the first pair of sides 13 and second pair of sides 14, and the secondary props 16 are at least in set from the second pair of sides 14.

The pallet 1 is able to be supported on rails of a rack, and the deck 10 of the pallet is accessible at its bottom for lifting by a forklift, when the pallet is oriented either with its first pair of sides 13 or its second pair of sides 14 substantially parallel to the rails of a storage rack.

Views of a potential storage rack 17 with which the pallet 1 may be used are shown in FIGS. 9A to 9B and 10A to 10B. As shown in these figures, the support rack 17 comprises a plurality of uprights 18 and a plurality of associated parallel rails 19. The configurations shown in FIGS. 9 and 10 are by way of example only, and any number of commonly used variations, such as variations in the height, width, and number of rows of rails 19 of the support rack 17 may be provided within the scope of the invention.

A first racking configuration of a pallet 1 is shown in FIGS. 9A and 9B. In this configuration, the first pair of sides 13 are oriented substantially parallel to the rails 19 of the support rack. When oriented relative to the rails 19 in this manner, the pallet 1 is supported on the rails 19 by the secondary props 16.

When supported on the secondary props 16 as shown in FIGS. 9A and 9B, a gap is to be provided between the rails 19 and the deck 10 of the pallet such that the tines of a forklift may be accommodated between the deck 10 and rails 19.

When supported on the secondary props 16, a pallet 1 may be accessible by a forklift from the side of the rack, that is in a direction perpendicular to the elongate direction of the rails 19.

Accordingly, the depth of projection of the secondary props 16 away from the bottom 12 of the deck 10 may be selected according to the application, such as for forklift tines of different thicknesses, or for different desired clearances for the forklift tines.

A second racking configuration is shown in FIGS. 10A and 10B. In this configuration, the second pair of sides 14 of the pallet are oriented substantially parallel to the rails 19 of the support rack 17. The pallet is supported on the rails 19 along the ledge 20 of the deck 10 which is located adjacent to each of the second pair of sides 14. Any secondary props 16 provided by the pallet 1 do not need to bear on the rails in this storage configuration. When supported on a rack 17 with the second pair of sides 14 substantially parallel with the rails 19, the pallet 1 is to be accessed by a forklift in a direction parallel to the elongate direction of the rails 19, that is, in a direction along the length of the support rack 17.

Preferably the width of the deck 10 between either of the pair of sides along which the pallet is to be supported by the rails 19 is greater than the gap between the two spaced apart rails 19 of the storage rack 17. For example, where the pallet is to be supported on the secondary props 16, the width of the deck 10 between the first pair of proposed sides 13 must be of greater width than the gap between the two parallel rails of the support rack 17. Similarly, if the pallet is to be supported on the ledges 20 of the deck 10, such that the second pair of sides 14 are oriented substantially parallel to the rails 19, the width of the deck 10 between the second pair of sides 14 must be greater than the gap between the rails 19.

Preferably in either supported orientation, the plurality of primary props are to be spaced inwardly adjacent and along at least one of the first pair of sides and second pair of sides, but preferably inwardly adjacent and along both pairs of sides. Thus, the primary props 15 will sit intermediate of the rails 19 of the storage rack when the pallet is supported by the rails.

Particular spacing of at least the primary props 15 relative to the rails 19 of a support rack 17 may also be desirable.

For the pallet configuration where it is edge supported at the ledges 20 on the rails 19, the spacing of the peripheral primary props 15 along the first pair of sides 13 may be used to control the movement of the pallet lateral of the two rails 19 when the pallet is edge supported on the rails. The primary props 15 are to sit intermediate of the rails 19. By providing the peripheral primary props 15 closer to their adjacent rail 19 than the gap between the rail and the outer edge 14 of the deck, the primary props may act to prevent the pallet from falling off the rails due to restricting the lateral movement of the pallet on the rails.

Similarly, the positioning of the primary props 15 along the second pair of sides 14 may be designed so as to limit the lateral movement of the pallet 1 relative to the rails 19 when the pallet is supported on the secondary props 16.

An example configuration of the distribution of the primary props 15 along the first pair of sides 13 so as to limit the lateral movement of the pallet on the rails 19 when the pallet 1 is edge supported on the ledges 20 of the deck is shown in FIG. 10B.

The secondary props 16 may be located along all sides of the pallet 1. They are preferably located outwardly more of the primary props 15 but may instead, at least in some instances be located inwardly of its adjacent primary prop 15.

Similarly, an example embodiment showing the distribution of the primary props 15 along the second pair of sides 14 such as to limit the lateral movement of the pallet 1 on the rails 19 when the pallet 1 is supported on its secondary props 16 is shown in FIG. 9B.

In some forms the arrangement of the primary props along the first pair of sides and the second pair of sides may be such as to prevent the pallet from slipping off the rails on which it is supported. In other forms, the spacing of the primary props may be act to lock the pallet laterally against the rails 19, in order to limit or even substantially prevent movement of the pallet lateral of the rails.

In order to accommodate the movement limiting relationship between the primary props 15 and rails 19 yet to prevent undesired engagement between the primary props 15 and the rails 19 particularly when loading one into the support rack 17 at least the peripheral portions of the primary props 15 may be provided with a lead in. Such a lead in may be characterized by the primary prop tapering away from the adjacent one of the first pair of sides 13 or second pair of sides 14 as the primary prop projects away from the base of the deck. For example, see the embodiment of FIG. 2 wherein the primary props 15 about the periphery of the deck 10 comprise a lead in such that at least their portions adjacent to the first pair of sides 13 and second pair of sides 14 taper away from the sides of the deck as the primary props extend downward.

The distance that the primary props extend below the deck is preferably greater than the distance the secondary props extend below the deck. The secondary prop distance may for example be 30 mm from the bottom of the deck. The primary prop distance may for example be 95 mm.

In a preferred form the top 11 of the deck 10 may be defined by a top panel that comprises a plurality of primary hollow depressions 21. These primary hollow depressions 21 are to correspond to the number of props 15, and to be shaped to nest with the primary props of another single deck pallet. Such primary hollow depressions 21 are seen for example in FIG. 1.

A cross section through two pallets 1 shown in a nested configuration is seen in FIG. 7.

In order to provide for a more complete nesting of single deck pallets of the present invention within each other in a stacked condition, the top panel of the deck of each pallet may further comprise a plurality of secondary hollow depressions 22 corresponding to the number and position of the secondary props 16. The secondary hollow depressions 22 are shaped to nest with the secondary props of another single deck pallet.

Where the single deck pallets are to be nested together, it may be desirable to limit the degree of nesting of the pallets with each other such that the tines of a forklift may still be able to be passed between the decks of the pallets in order to separate them. To this end, either or both the primary hollow depressions 21 or secondary hollow depressions 22, where present, may be provided with at least one tertiary prop 23. The tertiary props 23 according to one embodiment are shown in FIGS. 7 and 8. The tertiary props 23 extend from the base of the depressions upwardly towards the top 11 of the deck 10. The spacing of the decks of nested pallets from each other when in their nested condition may be controlled by varying the height of one or more tertiary props 23.

In one configuration, the top panel of the deck is of a plastic material. This may be compression formed, vacuum formed, or injection moulded, as examples. The primary props preferably define the primary depressions and the secondary props define the secondary depressions.

The pallet 1 as described above may but need not necessarily comprise props or depressions as described above. The pallet 1 may be of a simple configuration as shown in FIGS. 13C and 13D without any props or depressions. As shown in FIGS. 13 C and 13D, the pallet 1 may comprise a deck 10 with chassis 110 located below the deck 10 for supporting the deck 10.

Not relying on a twin deck construction, the single deck pallet 1 of the present invention as seen in FIGS. 13A, 13B, 13C and 13D gains strength from the frame or chassis 110 of metal beams 112. One example of chassis 110 is also shown in FIG. 16 that is a top view of the chassis 110 and FIG. 17 that is a bottom view of the chassis 110. The chassis 110 of metal beams primarily provide the load bearing capacity of the pallet 1/deck 10. When the pallet 1/deck 10 is for example edge supported along either the first pair of sides 13 or second pair of sides 14, beams of the chassis 110 extending across the gap between the rails, act in bending to carry the load on the pallet. The number of beams and their second moment of inertia in bending in such a manner are hence primary design factors.

In the preferred form the pallet 1 comprises of a deck of parallel beams extending in a first direction (i.e. from one of first opposed side 13 to another of the first opposed side 13) and parallel beams extending in a second direction (i.e. from one of second opposed side 14 to another of the second opposed side 14) being perpendicular to the first direction. Preferably there are 4 beams extending in each direction as shown in FIGS. 13A-13D. Preferably the beams 112 are hollow beams of constant quadrilateral (e.g. rectangular or square cross sections) as shown in FIGS. 18A-18F. The beams 112 are at least positioned as intermediate beams meaning the beams 112 are spaced from the sides 13, 14 and corners 113 of the deck/pallet. In other words, each of the beams 112 may be spaced apart (or spaced) from each of the sides 13, 14 of the deck 10 that is parallel to a longitudinal axis along which that beam extends. The beams 112 may also define or be located as perimeter beams of the pallet 1.

The perimeter beams 111 shown in FIGS. 13A and 13C are purely optional. This is because the load is typically placed in the middle of the pallet 1 and therefore it is the cross members/beams 112 that are located at the middle/intermediate portion of the pallet 1/deck 10 which need to be strong. As shown in FIGS. 13B and 13D, the chassis 110 comprise plurality of beams 112 running from or between the first pair of sides 13 of the pallet 1/deck 10 and beams running between the second pair of sides 13 of the pallet 1 and there is no perimeter beam 13 in the pallet 1. Each of the beams 112 are preferably of a hollow quadrilateral cross section (e.g. rectangular cross section) as seen in FIGS. 18A-18F.

The beams 112 extending between pair of sides 13 are preferable at right angles to the beams extending between pair of side 14. The beams 112 extending between pair of sides 13 are preferably also parallel to each other. Similarly, the beams 122 extending between pair of sides 14 are also parallel to each other as can be seen in FIG. 13A. Also, see FIGS. 16 and 17 which shows only the chassis 110 without the deck 10. As shown, the plurality of orthogonal beams 112 provides a grid formation (or grid) to act in bending to assist in pallet load support. By being hollow quadrilateral in cross section (e.g. rectangular or square cross section), the beams are oriented with vertical sidewalls 112A, 112A′ facing perpendicular to the plane of the deck 10 and horizontal sidewalls 112B, 112B′ facing parallel to the plane of the deck 10. The beams 112 may be positioned/arranged and are of a shape and configuration so that they can receive forklift tines to allow the pallet to be lifted.

At an intersection (such as an intersection I) of two beams of the grid, a first of the two beams preferably has both its vertical sidewalls 112A, 112A′ removed in order to allow a second of the two beams to pass through the first beam. An example of such a beam is shown in FIGS. 18A-E.

As shown in FIG. 18A, the beam 112 has both its vertical sidewalls 112A, 112A′ and one of the two horizontal sidewalls (top horizontal sidewall 112B) removed at the portion in which the beam 112 is configured to intersect with another beam. It will be appreciated that the top horizontal sidewall 112B of the beam 112 is the horizontal sidewall that is proximal to the deck 10 and bottom horizontal sidewall 112B′ is the wall that is distal to the deck 10 when the chassis 110 supports the deck 10. By removing the top horizontal sidewall 112B and two vertical sidewalls a notch 150 is formed on the beam 112.

FIGS. 19A-B show how two beams with such notch arrangement can be joined together to form a grid at each intersection I of beams 112 in the chassis 110. In FIGS. 19A-B, the first of the two beams is denoted by reference numeral 112′ and the second beam that passes through the first beam is denoted by reference numeral 112″. It will be appreciated that the second beam 112″ can be but need not of the same type as the first beam 112′. In other words, the second beam 112″ can be any suitable beam that is capable to be received within the notch 150 formed on the first beam 112′.

Hence, from the above, it can be appreciated that at the intersection of two beams 112′, 112″ of the grid, a first 112′ of the two beams may have both its vertical sidewalls 112A as well as one of the horizontal sidewalls (top horizontal all 112B that is proximal to the deck) removed to provide the notch 150 that allows a second 112″ of the two beams to pass through the first beam 112′.

Alternatively, it is possible that at the intersection of two beams 112′, 112″ of the grid, a first 112′ of the two beams may have both its vertical sidewalls 112A, 112A′ removed but the horizontal sidewalls (i.e. the top horizontal sidewall 112B that is proximal to the deck and the bottom horizontal sidewall 112B′ that is distal from the deck) is left unremoved and be continuous. Such configuration provides a slot 160 to be formed at the first beam 112′ that allows a second 112″ of the two beams to pass through the first beam 112″.

As shown in FIG. 18D, the beam 112 has both its vertical sidewalls 112A, 112A′ removed at the portion in which the beam 112 is configured to intersect with another beam. However, both the top horizontal sidewall 112B and the bottom horizontal sidewall 112B′ are not removed. It will be appreciated that the top horizontal sidewall 112B of the beam 112 is the horizontal sidewall that is proximal to the deck 10 and bottom horizontal sidewall 112B′ is the sidewall that is distal to the deck 10 when the chassis 110 support deck 10. By only removing the two lower vertical sidewalls, a slot 160 is formed on the beam 112.

FIG. 19C shows how with such a slot arrangement the two beams can be joined together to form a grid at each intersection I of beams 112 in the chassis 110. In FIG. 19C, the first of the two beams is denoted by reference numeral 112′ and the second beam that passes through the first beam is denoted by reference numeral 112″. It will be appreciated that the second beam 112″ can be but need not be of the same type as the first beam 112′. In other words, the second beam 112″ can be any suitable beam that is capable to be received within the slot 160 formed on the first beam 112′.

It can be appreciated that by having such configuration, there is less welding needed of two right angled orientated beams 112 at the junction/intersection of the grid. For example, at each grid or intersection/junction of two beams 112′, 112″, the welding may only occur at the vertical sidewalls of the beams. Little or no welding may occur at the horizontal sidewalls of the beams at the junction/intersection or the grid. In one configuration, welding may occur at the top horizontal sidewall on the beams. In one configuration, wielding may occur at top horizontal sidewall and vertical sidewalls of the beams, but no wielding may be required at the bottom horizontal sidewall 120B of the beams (see FIG. 20A). Since the bottom sidewall 112B of the first beam 112′ continuous to support the second beam 112″, the second beam 112″ cannot fall even when no welding is applied to the bottom horizontal sidewall 120B of the beams 112′ and 112″.

This can be advantageous because since less welding is required at the junction, risk of cracks being formed at the welded portion or any other damage that can typically occur at the wielded portion especially due to fatigue or due to load or overload of the pallet can be prevented or avoided completely. In particular the bottom horizontal sidewall 112B′ of one of both of the beams at the intersection are continuous. This means that the area of highest bending moment stress in a beam (at the bottom) both beams 112, 112″ have continuity of material. There is no discontinuity if the two beams 112′ and 112″ at the intersection were in a butting relationship where only one beam may have its bottom horizontal sidewall continuous.

FIG. 20B shows load L being applied at the beam. The tension T occurs at the bottom horizontal sidewall that supports the load. An example of a stress and stain diagram of the beam is also shown in FIG. 20 B.

As shown in FIGS. 13A and 13C, the grid of metal beams may comprise perimeter beams 111 but as mentioned above such perimeter beams 111 are purely optional. The perimeter beams 111 may meet at corners 113, the corners 113 being either a right-angled corner or a chamfered corner. Chamfered corner as in the preferred form is shown in FIG. 13A-FIG. 13D. The corner may also be rounded. The chamfered construction at the corners of the perimeter beams provides additional strength to the corner regions of the pallet. The corner regions 113 may additionally carry shock absorbing elements such as for example shown at the bottom left hand corner in FIG. 13A showing shock absorber 114. The shock absorber may be made of a rubber or plastic material.

In a one example, the perimeter beams 111 are of a C or U section shape. In the preferred form the region 116 of the C shaped perimeter beam 111 is the outer most portion of the frame 110. The beams could also be box or trapezoidal shaped.

Alternatively, and more preferably, the perimeter beams 111 may also be of a hollow quadrilateral cross section (e.g. rectangular cross section) similar to the beams 112. At the grid where perimeter beam 111 and beam 112 intersect, either the perimeter beam 111 or beam 112 preferably has both its vertical sidewalls 112A removed in order to allow a second of the two beams 111, 112 to pass through the first beam. It is possible that at the intersection of two beams 111, 112 of the grid, one of the two beams 111, 112 preferably has both its vertical sidewalls 112A as well as one of the horizontal sidewalls removed in order to allow a second of the two beams to pass through the first beam. As mentioned above, perimeter beams 111 are purely optional and in the most preferred embodiment preferably the pallet has no such perimeter beams 111.

FIG. 21A-E show another example of a chassis 210 that may be used or be part of the pallet 1 as described above. FIG. 21A shows a bottom perspective view of the metal framework of the chassis 210 of the deck for use in several embodiments of a pallet 1 as described above. FIG. 21B is a bottom plan view of the chassis of FIG. 21A. FIG. 21C shows a view in direction XX of the chassis of FIG. 21B, FIG. 21D shows a view in direction YY of the chassis of FIG. 21B. FIG. 21E is a top plan view of the chassis of FIG. 21A.

As shown, the plurality of orthogonal beams 212A-212L provides a grid formation to act in bending to assist in pallet load support.

FIGS. 22A-22F show detailed views of various sections of FIGS. 21B and 21E. Specifically, FIG. 22A shows a detailed view of section C of FIG. 21B. FIG. 22B shows a detailed view of section D of FIG. 21B. FIG. 22C shows a detailed view of section E of FIG. 21B. FIG. 22D shows a detailed view of section F of FIG. 21B. FIG. 22E shows a detailed view of section G of FIG. 21E. FIG. 22F shows a detailed view of section H of FIG. 21E. FIG. 22G shows a cross-sectional view along direction VV of FIG. 21C. FIG. 22H shows a cross-sectional view along direction ZZ of FIG. 21E. In FIGS. 22A-22F welded portions W are also shown. The welded portions W are shown just as an example. The chassis of FIGS. 21A-E need not be welded in the exactly the same manner as shown in FIGS. 22A-F and lesser welding than what is shown in FIGS. 22A-F are equally possible.

FIGS. 23A-23D show how beams 212A-212H may look like. Specifically, FIG. 23A shows a perspective view of one of the beams (although labelled as 212A, it may be any one of the beams 212A-212H). FIG. 23B shows an end view of the beam 212A of FIG. 23A. FIG. 23C shows a top plan view of the beam 212A of FIG. 23A. FIG. 23D is a side view of the beam of FIG. 23A.

Similarly, FIGS. 24A-24D show how beams 212I-212L may look like. Specifically, FIG. 24A shows a perspective view of one of the beams (although labelled as 212I, it may be any one of the beams 212I-212L). FIG. 24B shows an end view of the beam of FIG. 24A. FIG. 24C shows a top plan view of the beam of FIG. 24A. FIG. 24D is a side view of the beam of FIG. 24A.

As shown the beams 212A-212L may of hollow quadrilateral in cross section (e.g. rectangular or square cross section). By being of such cross section, the beams may be vertical sidewalls 213A, 213B, 213C, 213D facing perpendicular to the plane of the deck 10 and horizontal sidewalls 215A, 215B, 215C, 215D facing parallel to the plane of the deck 10.

The beams 212A-212L may be positioned/arranged and are of a shape and configuration so that they can receive forklift tines to allow the pallet to be lifted.

As shown in FIG. 24A, at an intersection (such as an intersection J) of two beams of the grid, a first of the two beams preferably has both its vertical sidewalls 213C, 213D removed in order to allow a second of the two beams to pass through the first beam. Also as shown in FIG. 24B, the beam 2211 may have both its vertical sidewalls 213C, 213D and one of the two horizontal sidewalls (top horizontal sidewall 215C) removed at the portion in which the beam 112 is configured to intersect with another beam (which is preferably any one of beams 212E-212H). It will be appreciated that the top horizontal sidewall 215C is the horizontal sidewall that is proximal to the deck 10 and bottom horizontal sidewall 215D is the wall that is distal to the deck 10 when the chassis 210 supports the deck 10. By removing the top horizontal sidewall 112B and two vertical sidewalls a notch 250 is formed on the beam 212I, 212L.

FIG. 22C shows how two beams with such notch arrangement can be joined together to form a grid at each intersection J of beams 212E-212L in the chassis 210.

It can be appreciated that by having configuration as described above, there is less welding needed of two right angled orientated beams 212E-212L at the junction/intersection of the grid. The detailed views of FIGS. 22A-22F shows an example of where the wielding W may be required. Preferably the welding may only be required at each grid or intersection/junction of two beams. The welding may only occur at the vertical sidewalls of the beams. Little or no welding may occur at the horizontal sidewalls of the beams at the junction/intersection or the grid.

Due to less welding required at the junction, risk of cracks being formed at the welded portion or any other damage that can typically occur at the wielded portion especially due to fatigue or due to load or overload of the pallet can be prevented. The corners may be L shaped as shown in FIGS. 21A-E. The corner may comprise corner brackets 217. FIG. 25 shows an example of a corner bracket that may be welded (see FIG. 22A where welded regions are shown by W) or otherwise attached to each corner of the chassis. regions 217 may additionally carry shock absorbing elements such as a shock absorber. The shock absorber may be made of a rubber or plastic material.

Therefore, from the above it will be appreciated that the pallet 1 of the present invention may comprise a deck/pallet deck for receiving the load thereon and a chassis 110, 210 (such as shown in FIGS. 16,17, 21A-21E) below the deck 10 for supporting the deck 10. The deck having a top portion 118 for supporting the load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides 13 and a second pair of opposed sides 14. The chassis 110, 210 is in a grid formation as shown in FIGS. 16,17, 21A-21E. As shown, the chassis 110, 210 comprises a first set of at least two spaced apart and parallel beams extending between the first pair of opposed sides of the deck but spaced apart from the second pair of opposed sides of the deck. Also, as shown in FIGS. 13D-13D, 16 17, 21A-21E, a chassis 110, 210 also comprises a second set of at least two spaced and parallel beams extending between the second pair of opposed sides of the deck but spaced apart from the first pair of opposed sides of the deck. The first set of beams are orthogonal to the second set of beams. At each intersection of two beams of the grid a first of said two beam has a notch 150, 250 or a slot 160 to allow a second beams to pass through the first beam.

In the preferred form all of the beams 112,212A-212L are co-planar. In the preferred form all of the beams 112, 212A-212L are of the same height so as together, to define the bottom 12 of the deck 10. The bottom portion 12 of the deck is hence of a planar (though a discontinuous grid of beams) configuration allowing for forklift tines to support the deck at the bottom surface.

The frame/chassis 110, 210 is optionally enveloped by a plastic. The plastic may define the top panel 118 that defines the top 11 of the pallet 1. In the preferred form the plastic may also extend about the perimeter of the perimeter beams and also over the bottom of the beams to define the bottom of the pallet 1. The plastic envelope of the frame may be provided of at least two parts of plastic that are bonded together. The primary part defining the top panel 118 and props and the additional part or parts being plastic received by the frame from below. The top panel may be made from a fibre reinforced plastic. The top panel may be adapted and figured to help keep the beams in column during bending rather than deviating laterally during bending.

Alternatively, the plastic may merely define the top panel 118 and the primary and secondary props 15, 16, the frame 110 being secured or otherwise bonded to the plastic.

In some forms the plastic may be compression moulded about the beam grid 110 or injection moulded about the beam grid.

The top panel is where goods or a load is supported on the pallet. The load may be evenly distributed across the beams. However, in many situations, a pallet may have an uneven load distribution. In addition, a pallet may be picked up by the tines of a forklift in a manner to cause an uneven load distribution and point loading of the tines of a forklift on the bottom of the deck. In addition, forklifts may hit the sides of the deck as speed and this may cause damage to the pallet.

With reference to FIG. 15a it can be seen that when a forklift picks up a pallet 1 the tines 100 of a forklift may contact the bottom of the deck 10 (i.e. the bottom of the beams of the deck) in a manner to create a point load as seen in FIG. 15a. This point load L on beam or beams 112,212A-212L may result in the creasing or crushing of the wall of the beam 112, 212A-212L at the bottom of the deck. One way to avoid this point loading damaging the bottom of the beam, thereby potentially decreasing the strength of the pallet, is to increase the gauge thickness of the beam 112, 212A-212L. However, increasing the gauge thickness increases the weight of the beam or beams and hence then the weight of the pallet. Given that the most likely location for lifting mode damage to occur by a forklift is to the beams 112, 212A-212L at the bottom region of the beams, it has been found that enhancing the strength of the beams at the bottom region is able to be achieved without substantially increasing the weight of the beams 112,212A-212L.

The beams 112, 212A-212L are still able to be manufactured from a thin gauge cold rolled steel sheet yet provide enhanced resistance to creasing/bending due to tine point loading where it is needed such as by an engineered wall profile such as region 130, 230 as seen in FIGS. 18A-18E, 23B, 24B at the bottom surface 131, 231 of the bottom sidewall 1126′, 2156, 215D. The engineered profile at region 130, 230 is for example an internal flange extending into the hollow section of the rectangular cross sectioned beam as seen in FIGS. 18A-18E, 23B and 24B. The engineered profile enhances the second moment of inertia of the bottom of the beam and as a result enhances the resistance of this region of the beam to creasing damage or impact damage resulting from for example point loading of the end of a forklift tine on the bottom of the beam. In other words, the beams 112, 212A-212L may remain of a thin gauged steel but may have a form at the bottom region for enhancing the strength at the bottom region. This allows for the beams 112, 212A-212L to still remain of a low weight given that such enhanced strength formations are not required in other parts of the beams.

In alternative forms the strength of the bottom of beams 112, 212A-212L may be enhanced by forming the thin gauged sheet in a way so as to double the layers of the sheet at the bottom surface.

Likewise, the perimeter beams (if present) may have a doubling of sheet metal at the bottom to also help resist impact damage of the perimeter beams at the bottom. Hence forming the sheet metal to define the beams in a matter to enhance localised strength of the beams can be achieved instead of enhancing the thickness of the gauge of sheet metal used to form the entire beam, thereby providing weight savings.

The doubled region of the beam preferably extends along the entire length of the beam. But in an alternative configuration, the doubled region may be provided intermediate of the ends of the beam yet still provide enhanced bend resistance.

As discussed above forklift tines 100 are able to reach under the deck 1 at locations between the primary props 15. The horizontal spacing between the primary props 15 is such as to allow for sufficient width-wise clearance between props for a tine of the forklift.

To ensure that forklift tines (typically 100 mm wide) contact the bottom of the pallet at where the beams 112 are provided (beams 112 extending in the fork-wise direction) are preferably located between the gaps between the primary props. A gap G can be seen in FIG. 13 for a forklift tine 100 (of FIG. 13E) to pass through. The forklift tine 100 will come to bear on the beam(s) 112. When the pallet is for example stored on the ground, with the primary props supporting the pallet on the ground, the only gap for forklift tines to pass under the deck is at the gap or gaps between adjacent primary props. Given that forklift tines are typically of a width W of 100 mm wide, the gap G between primary props and the positioning of the beam(s) 112 in the gap is preferably such that the forklift tine is always going to come into contact with a beam 112 or where provided both or multiple beams 112 extending between a gap G of adjacent primary props.

In one example, the distances K are preferably less than 100 mm so that if a forklift tine abuts against a primary prop, at its other side the tine sits under the beam 112. Likewise, the distance K2 between beams may be less than 100 mm so that a forklift tine cannot slip between the gap between the parallel intermediate beams as shown in FIG. 13. In one example, for example the spacing K and K2 is about 70 mm. Likewise, the spacing may be such in the other direction but has not been described in detail but will be appreciated by a person skilled in the art how this would work in order to ensure that a forklift tine reaching under a deck of a pallet will always come to bear on an intermediate beam of the pallet. The spacing on the other axis may be different as to the axis as show.

It will be appreciated that in FIG. 13E only one forklift tine is shown however two forklift tines are usually used for lifting a pallet, the other forklift tine entering the gap adjacent to the gap described above. As mentioned above forklift tines can also reach below the deck in a direction lateral to the direction shown in FIG. 13 between gaps of adjacent primary props spaced in the other direction.

The pallet of the present invention may be able to be made of a light weight construction. This helps reduce shipping/return costs. It also allows the pallet to be handled by hand. As an example, some weights of pallets that are able to be edge supported and able to support an evenly distributed load of 2500 kg may be as follows:

• • (a) 1200×800—around 18 kg
  • (b) 1200×1000—around 22 kg.

The pallets may nest to around 50% or better of their height creating further savings on return shipping costs.

The deck of the pallet primarily defined by the height of the metal frame/chassis plus plastic may be between 30 and 60 mm in height.

The use of a thin gauge metal sheet, preferably cold rolled into the desired beam shape preferably allows for at least one of the intermediate beams and perimeter beams to remain of a light weight construction yet have localised reinforcing (such as by providing an engineered profile and/or a doubling up of the layers of the sheet metal at certain locations) to improve impact/crease resistance. In the preferred form the steel gauge used is preferably between 0.045 to 1.8 mm in thickness. Preferably the sheet gauge is 1 mm in thickness. Examples of dimensions and other characteristics of example profiles that can be used for the perimeter and/or intermediate beams is shown below.

The beams 112, 212A-212L may be made from a single sheet, or two sheets of half the profile each, of cold rolled steel, formed into a box shape with either continuous or spot welds joining the 2 ends of the sheet where required. Parameters:

TABLE 1
Preferred Profile
Steel type            Cold rolled
                      Range of strengths
                      Coated or not coated
                      Std or high tensile
Steel gauge           0.045 mm to 1.80 mm
Height of box section 10 mm-60 mm
Top width             5 mm-80 mm
Length of down turns  0 mm - 60% of height of I-beam
Length of up turns    As with down turns (not shown). NOTE: If up
                      turns are present, do not necessarily need
                      to have down turns and vice versa.
Bottom Width          5 mm-80 mm
Welding               Stitch or continuous weld along bottom seam,
                      such that the two halves on the bottom are
                      held together when under load.
Example dimensions    a = 38 mm b = 30 mm c = 18 mm d = 18 mm
                      e = 4

Load distribution has potentially a much more detrimental effect on performance of the pallet than the quantum of the load. As seen in FIG. 15B a pallet having a centrally applied load between each side supports (such as the rails 19 of the rack) will result in a substantially even bend profile of the beams of the deck extending between the rails. However as seen in FIG. 15B an uneven load distribution of a pallet may result in an uneven bend profile and as a result a higher curvature R1 at and/or near one of the rails 19 compared to R2 at or near the other opposite rail. The higher curvature R1 (even though the load L in FIG. 15A may be the same as the load L in FIG. 15B) can result in goods stacked on the pallet from toppling more readily in region R1 given the slope of region of the top of the pallet on which the goods are sitting on. Hence in designing the pallet it is important to take account of uneven load distribution and ensuring that the beams are sufficiently rigid to not either bend to failure or result in a significant slope of the top of the pallet being established which could potentially destabilise the goods on top. The goods may also also crush onto themselves due lean that they may be on.

It will hence be appreciated that the design of the pallet as described above may achieve a good and desirable outcome for carrying loads of up to two tonnes on the pallet and hence having sufficient strength yet able to be nested by virtue of a decrease in the thickness of the deck and/or not by providing a twin deck format. In addition, the tension between weight of the pallet and the strength of the pallet is also suitably provided uncompromised. The pallet is sufficiently strong yet is sufficiently light to be handled by hand. In addition, the pallet is able to handle a substantial degree of wear and tear and potential damage from for example forklift tines.

Whilst herein described are pallets such as a shipping pallet comprising of a deck and primary props and preferably secondary props it will be appreciated that the deck is also able to be used as part of a shipping crate such a crate comprising of a deck as herein described and sidewalls extending vertically above the deck. The sidewalls may define an enclosure/crate within which goods can be stored. The sidewalls may also assist in load transfer of a plurality of like stacked crates from one pallet to the other at the edges of the deck rather than via props that are located intermediate of the footprint of the crate.

The invention herein described also comprises a system of nesting single deck pallets as herein described in combination with standard racking and preferably also drive through racking. It will be appreciated that the pallets that have herein been described can lend themselves for use in standard and/or drive through racking.

The pallet of the present invention is preferably made of non-bio material. The pallet is preferably made from plastic and metal.

The pallet is preferably a four-way pallet allowing fork entry from four sides of the pallet. Preferably the entry ports (the gaps) between adjacent primary props are the same height at all sides based on the fact that the primary props extend an equal distance from the deck.

The optional perimeter frame can be provided to facilitate the storage of the rack in drive through racking. The ledge at the exterior of two parallel sides of the deck, outside of the primary props, allows for drive through racking of the pallet. And again, working in conjunction with the props being spaced approximate to the rails of the drive through racking will help hold the pallet on the rails of the drive though racking and prevent the pallet from sliding off the racking.

The props and corners may be replaced if damaged.

Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth.

Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and/or improvements may be made without departing from the scope or spirit of the invention.

Claims

1. A pallet for carrying a load and is able to be lifted by tines of a fork lift, the pallet comprising a planar deck for receiving a load thereon and a chassis below the deck for supporting the deck, the chassis comprising a plurality of hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical side walls facing perpendicular to the plane of the deck and horizontal side walls facing parallel to the plane of the deck,

wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.

2. The pallet as claimed in claim 1, wherein the beam with the sidewalls removed at the intersection has at least some of its bottom horizontal sidewall continuous over the intersection and is parallel and adjacent, and touches the bottom horizontal sidewall of the beam that passes through the first mentioned beam.

3. The pallet as claimed in claim 1, wherein the beam with the sidewalls removed at the intersection has at least some of its top horizontal side wall continuous over the intersection and is parallel and adjacent, and touches the top horizontal side wall of the beam that passes through the first mentioned beam.

4. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam has no cut-outs across of adjacent the intersection.

5. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam is of a constant cross section across and adjacent the intersection.

6. The pallet as claimed in claim 1, wherein the beam that passes through the first mentioned beam is welded to the first mentioned beam at regions where sidewalls of the two beams are adjacent each other.

7. The pallet as claimed in claim 1, wherein the pallet is a shipping pallet.

8. A pallet as claimed in claim 1, wherein the grid is provided of at least two first set of said beams extending between a first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck.

9. The pallet as claimed in claim 8, wherein at least one of the first and second set of beams define a bottom portion of the deck at where the tines of the forklift is able to engage to lift the pallet.

10. The pallet as claimed in claim 1, wherein a bottom of at least one of the beams is provided with at least one of (a) an engineered profile (b) a double wall of said sheet material.

11. The pallet as claimed in claim 10, wherein the engineered profile and/or the double wall of said sheet material is provided in a manner to increase bend resistance at the bottom of the beam.

12. The pallet as claimed in claim 10, wherein the engineered profile and/or the double wall of said sheet material is provided in a manner to increase second moment of inertia at the bottom of the beam.

13. The pallet as claimed in claim 10, wherein the beams of at least one of the first and second set of beams are quadrilateral in cross section and the engineered profile is a flange of said sheet metal extending into the interior or the beam.

14. The pallet as claimed in claim 10, wherein the beams comprise of both a single ply of said sheet material wall construction and double ply of said sheet material wall construction.

15.-23. (canceled)

24. A pallet for carrying a load and is able to be lifted by tines of a forklift, the pallet comprising a planar deck for receiving the load thereon and a chassis below the deck for supporting the deck, the deck having a top portion for supporting the load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the chassis being in a grid formation and comprising a first set of at least two spaced apart and parallel beams extending between the first pair of opposed sides of the deck but spaced apart from the second pair of opposed sides of the deck, and a second set of at least two spaced and parallel beams extending between the second pair of opposed sides of the deck but spaced apart from the first pair of opposed sides of the deck, wherein at each intersection of two beams of the grid a first of said two beam has a notch or a slot to allow a second beams to pass through the first beam.

wherein the first set of beams are orthogonal to the second set of beams,

25. The pallet as claimed in claim 24, wherein the beams are hollow beams of constant quadrilateral cross section, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck.

26. The pallet as claimed in claim 24, wherein the notch or the slot is formed by removing both the vertical sidewalls of the said first beam.

27. The pallet as claimed in claim 24, wherein the slot is formed by removing both of its vertical sidewalls removed and one of the horizontal sidewalls of said first beam, one of the horizontal sidewalls being proximal to the deck.

28. A single deck pallet comprising:

a deck having a top portion for supporting a load and a bottom portion opposite the top portion, at least four sides, the at least four sides comprising a first pair of opposed sides and a second pair of opposed sides, the bottom portion comprising a chassis, the chassis comprising a plurality of orthogonal hollow beams of constant quadrilateral cross section in a grid formation to act in bending to assist in pallet load support, the beams spanning parallel to the plane of the deck and each oriented with vertical sidewalls facing perpendicular to the plane of the deck and horizontal sidewalls facing parallel to the plane of the deck,

wherein at intersections of two beams of the grid a first of said two beams has both of its vertical sidewalls removed to allow a second of said two beams to pass through the first beam.

29. The pallet of claim 28, wherein the grid formation is provided of at least two first set of said beams extending between the first pair of opposed sides of the deck and at least two second set of said beams extending between a second pair of opposed sides of the deck.

30.-50. (canceled)