AU2007200209B2 - An Improved Pallet - Google Patents

Abstract

Abstract The invention provides an improved pallet comprising a pallet, at least one strap, and at least one block, wherein the block is inserted between an upper and'lower surface of the pallet, and the strap is secured around the upper and lower surfaces of the pallet to encompass the block. The invention also provides a method of manufacturing the improved pallet, and a kit for use in the method. Figure 3 of1 Figure 4 /2t Figure 5

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Invention Title: An Improved Pallet Address for Service: CULLEN & CO. Level 26 239 George Street Brisbane Qld 4000 Applicant: Dundee Holdings Pty Ltd The following statement is a full description of the invention, including the best method of performing it, known to us: FIELD OF THE INVENTION The present invention is directed to pallets, in particular pallets with improved performance. BACKGROUND ART Pallets are used extensively in Australia and indeed worldwide, to transport and store many items. Since the advent of mechanisation of material handling, pallets have been used as a platform for the efficient and safe transportation of items for supermarkets, hardware stores, for medical items, machinery and parts, and building materials. In fact just about any item used by the modem consumer society can and has been transported and/or stored on a pallet. Combined with heat shrink plastic wrapping, items placed on a pallet can be stored, loaded, relocated and unloaded by mechanised forklifts and transported by, for example, trucks, trains, barges and aircraft, safely and quickly to any point on the globe. Timber pallets in particular can be made of softwoods such as pine, or hardwoods. The softwood pallets are "one use" and disposable, usually by burning, which is very wasteful. The hardwood pallets are re-used, but suffer extensive and often fatal damage by weathering, being dropped, struck by the tines of the forklift and general attrition. With the increasing cost and scarcity of timber in general and hardwoods in particular, many countries such as the USA have moved to using plastic pallets. While these pallets have the advantage of relative individual cheapness and ability to be stacked and stored very efficiently, they are not as safe as timber pallets. The plastic pallets easily fall off the tines of a forklift, and result in damage to the items on the pallet, and possible injury to persons in that vicinity. Therefore, there would be an advantage if it were possible to provide an improved pallet which may overcome at least some of the above-mentioned disadvantages or provide a useful or commercial choice. SUMMARY OF THE INVENTION In a first embodiment, the invention provides an improved pallet comprising a pallet, at least one strap, and at least one block, wherein the block is inserted between an 2 upper and lower surface of the pallet, and the strap is secured around the upper and lower surfaces of the pallet to encompass the block. In a second embodiment, the invention provides a method of manufacturing an improved pallet, the method comprising inserting at least one block between an upper and lower surface of a pallet and securing at least one strap around the upper and lower surfaces of the pallet to encompass the block. In a third embodiment, the invention provides a kit when used in the method of the second embodiment, the kit comprising: a pallet, at least one block; at least one strap, and instructions for securing the block and strap to the pallet. With regard to the first, second and third embodiments of the invention defined above, the pallet can made of any practicable material, for example plastic or timber. For the purposes of the invention, timber pallets are preferred. The invention can be effected on an existing or used pallet, or effected during manufacture of a pallet de novo. The pallet is generally of conventional configuration, being a timber pallet comprising between 4 and 7 boards on a lower surface, 6 or 7 boards on an upper surface, and 3 joists separating upper and lower surfaces. Nails secure the upper and lower boards to the joists. The boards used are generally 100mm x 25mm with the three joists being generally 75mm x 50mm. The aforementioned construction creates a timber platform 1200mm x 1200mm that can be lifted using a standard forklift. The block can be of any appropriate material, for example plastic or a composite material, but is preferably timber. The block is of a size that enables insertion between the upper and lower surfaces of the pallet. The block is preferably of a length substantially equivalent to the width of one of the boards comprising the upper or lower surface of the pallet. The block can be secured in position by any practical means. For example, the block can be of such a size that it is secured in place by the pressure of the upper and lower surfaces of the pallet, or glued into place. Alternatively, and preferably, the block is secured in place by skew-nailing at least one nail through the block and the inside joist adjacent to the block. Additionally, at least one nail can be skew-nailed through the upper surface of the pallet and the block, and through the lower surface and the block. 3 The strap securing the block between the upper and lower surfaces of the pallet can be of any practical material and configuration, but is preferably a steel strap of approximately 19 mm. The strap is preferably secured by placing the strap under tension. The blocks and straps are preferably placed at each of four corners of the pallet, with each of four straps surrounding a block and the end boards of the upper and lower surfaces of the pallet. In order to further strengthen the improved pallet, all boards on the upper and lower surfaces of the pallet are preferably skew-nailed with at least one nail per board, to the joists. The improved pallet is further modified to improve safe handling thereof by painting the improved pallet. This increases the visibility of the pallet to forklift drivers and enables them to more accurately direct the forklift tines to the space between the upper and lower surfaces of the pallet. In doing this, the life of the pallet is increased, and the safe lifting of the pallet is improved. The improved pallet can be painted any colour, but is preferably painted in a highly visible colour, such as white. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a conventional pallet, with a board absent from the upper surface. Figure 2 shows the strap being secured under tension to a pallet of the invention. Figure 3 is a side view of a corner of an improved pallet of the invention. Figure 4 is a top view of a corner of an improved pallet of the invention. Figure 5 shows a portion of a pallet of the invention with forklift tine. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 shows a conventional pallet, made with upper (I) and lower (2) surface boards of about 100mm x 25mm, with two end joists (3) and a central joist (4) of 75mm x 50mm. The resulting timber pallet of about 1200mm x 1200mm can be lifted by a forklift by insertion of the forklift tines between the end (3) and central (4) joists, under the upper surface boards (I). With reference to Figures 2 and 3, a pallet of the invention is made by inserting a 4 block (5) of either hardwood or softwood of about 75mm x 40mm x 150mm between the upper (6) and lower (7) surfaces of a pallet (8), such that the block is a length equivalent to the width of the end board of the upper surface (9) and the end board of the lower surface (10). Also with reference to Figure 4, the block (5) is skew-nailed with nails (11) through the upper surface board (9), lower surface board (10) and joist (3). Additional nails are skew-nailed through the upper boards (9) and joist (3) and lower boards (10) and joist (3). A 19mm steel strap (12) is placed under tension around each upper (9) and lower (10) board, to encompass each block (5). It will be clear from the Figures, and in particular Figure 5, that the block (5) provides added strength to the pallet, and protects the strap (12) from the forklift tines (13). All remaining upper and lower surface boards are further secured by skew-nailing to the joists. A kit of the invention comprises at least one block (5), at least one strap (12), at least one nail (11), and instructions for modifying a pallet in accordance with the invention. Optionally the kit contains paint appropriate for painting the pallet. Use of the kit of the invention in the method disclosed herein provides a much improved and strengthened pallet that is uncomplicated and inexpensive to produce. TESTING OF THE IMPROVED PALLET OF THE INVENTION Description of Test Pallets I. Standard hardwood timber pallets having 100 x 25 planks nailed to the upper and lower of three 75 x 50 runners to form a 1200 x 1200 timber platform that is able to be hoisted with a standard forklift. 2. The improved pallet has additional timber blocks and steel straps on the four comers to more securely hold the leading upper and lower planks. 5 Test Lifts The test procedure was set up using a forklift, one standard pallet and one improved pallet, as defined above. Testing was carried out on each pallet type, using certified 2 tonne and I tonne weights, as follows: . 2T correctly lifted . 2T incorrectly lifted - forks tilted downwards - 2T incorrectly lifted - forks partly inserted . 2T and IT correctly lifted . 2T and IT correctly lifted . 2T and IT incorrectly lifted - forward or partly inserted . Improved pallet steel strap damaged Observations Observations were made during the testing and results recorded below. I. Both the standard pallet and improved pallet performed normally on the 2T lift. 2. With forks tilted forward, the pallet is lifted from the rear first which puts extra prying forces on the rear horizontal board. 3. When the forks are not fully inserted the affects on the rear board can be the same as when the forks are tilted forward. 4. Both pallets performed acceptably when correctly lifted with 3T. 5. When lifted incorrectly the improved pallet rear board was protected by its straps and did not disconnect from the pallet. To simulate a situation where a forklift cannot get good access to the full underside of the pallet through broken boards or other reasons an extreme test was done. 6 There was an attempt to move the pallet with the forks under the rear board only. The improved pallet withstood this test with a 3T load. This test was repeated with the standard pallet and a 2T load. This lift was repeated on the other rear board using the standard pallet, again with a 2T weight, to check consistency of result. The rear board failed again in a similar way at 2T. A nick in the improved pallet steel strap was made using the forklift tine to simulate an accidental cut. The ultimate test on the rear board, using the ends of the tines, was repeated with the weakened strap. As expected the weakened strap ruptured first and at a lower lifted weight but still higher than the lift required to pry off the rear board of the standard pallet. A correct lift on this pallet still managed 3T. The other rear board of the improved pallet was similarly loaded to pry off using the 3T load. On this end there was an incomplete crimp on one steel strap and this crimp ruptured first, but not before lifting the rear of the pallet clear of the ground (still carrying the 3T load). Conclusions I. Normally the pallets fail through incorrect lifting procedures and very frequently it is the rear boards. 2. A heavy object breaking one of the middle boards will often require the operator to attempt a partial list on the rear boards because the fork tines can no longer penetrate fully. 3. In the tests of these two pallets, the improved pallet easily outperformed the standard one when subject to slightly incorrect lifting procedures. 7 4. Overall, the test indications are that in normal abnormal mixed use, the improved pallet gives a greater service life. It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the present invention without departing from the spirit or scope of the invention as broadly described. The above examples are therefore to be considered in all respects illustrative and not restrictive. The term "comprise" and variants of the term such as "comprises" or "comprising" are used herein to denote the inclusion of a stated integer or stated integers but not to exclude any other integer or any other integers, unless in the context or usage an exclusive interpretation of the term is required. Any reference to publications cited in this specification is not an admission that the disclosures constitute common general knowledge in Australia. 8

Claims (12)

1. An improved pallet comprising a timber pallet, at least one strap, and at least one timber block, wherein the block is inserted between an upper and lower surface of the pallet, and the strap is secured around the upper and lower surfaces of the pallet to encompass the 5 block, and wherein the pallet further comprises at least one nail, the at least one nail being skew-nailed into the pallet and the block.

2. The improved pallet of claim 1, wherein the strap is a steel strap.

3. The improved pallet of claim 1 or claim 2, wherein the improved pallet is painted.

4. The improved pallet of claim 3, wherein the improved pallet is painted white. 0

5. A method of manufacturing an improved pallet, the method comprising: inserting at least one timber block between an upper and lower surface of a timber pallet; skew-nailing at least one nail into the pallet and the block and securing at least one strap around the upper and lower surfaces of the pallet to 5 encompass the block.

6. The method of claim 5, wherein the strap is a steel strap.

7. The method of claim 5 or claim 6, wherein the block is inserted in four corners of the pallet.

8. The method of any one claims 5 to 7, further comprising painting the pallet. 20

9. The method of claim 8, wherein the paint is white.

10. A kit when used in the method of claim 5, the kit comprising: a timber pallet; at least one timber block; at least one strap; 25 at least one nail; and instructions for securing the block and strap to the pallet.

11. An improved pallet substantially as hereinbefore described with reference to the Figures.

12. A method of manufacturing an improved pallet substantially as hereinbefore described 30 with reference to the Figures.