US20240217701A1

US20240217701A1 - Top frame for pallet system

Info

Publication number: US20240217701A1
Application number: US18/397,687
Authority: US
Inventors: Yaw-Kuen Lin
Original assignee: Inteplast Group Corp
Current assignee: Inteplast Group Corp
Priority date: 2022-12-30
Filing date: 2023-12-27
Publication date: 2024-07-04

Abstract

A top frame used to stabilize articles supported on a pallet allows the stabilized articles to have greater lateral stability. The top frame is formed by two frame members that can be snapped together to form the top frame. The top frame members can have the identical construction for ease of manufacturing.

Description

STATEMENT OF RELATED CASES

This application is the nonprovisional of provisional application Ser. No. 63/477,848, filed Dec. 30, 2022, the contents of which are incorporated herein in its entirety.

FIELD

This invention relates generally to pallets and more specifically to a top frame used in a pallet system.

BACKGROUND

Pallet systems are used to support products for storage and easy conveyance to an end location, such as a point of sale location for consumer products. Pallet systems include a base pallet that is usually constructed for use with a forklift or pallet jack to be lifted off the floor for conveyance to another location. It is common for products to be arranged in a stack formed from multiple rows of product separated by dividing panels. Stacked products can be unstable laterally and so pallet systems are constructed to provide stability. In that regard, the base pallet is of sturdy construction to avoid deformation when carrying the load. The dividing panels preferably have enough rigidity so that each row of product is on a flat surface of stable configuration. In addition, it is known to provide straps over the top of the stack to essentially tie the stack to the base pallet. However, the divider panels are typically too thin to provide resistance to laterally inward deformation when tightly wrapped with straps.
Accordingly, it is known to provide as part of the pallet system a top frame that has more lateral rigidity than the divider panels. The top frame is usually thicker and capable of resisting lateral deformation when loaded by the straps applied around the pallet system at the products stacked on the pallet system. The top frame and straps give a substantial degree of structural stability to the pallet system so that the products can be moved around with minimal chance that the stacked products will topple over.

SUMMARY

In one aspect of the present invention, a top frame for use in a pallet assembly to stabilize articles held on a pallet generally comprises a first top frame member including first mechanical connection units. A second top frame member including second mechanical connection units, the second top frame member is configured to be secured to the first top frame member with the first mechanical connection units connected to the second mechanical connection units.
In another aspect of the present invention, a top frame member for use in forming a top frame configured for use in a pallet assembly to stabilize articles held on a pallet generally comprises a generally rectangular frame having an exterior including a flat surface, an interior including ribbing supporting the flat surface. Mechanical connections arranged around the frame are configured for snap together mating with mechanical connections of another top frame member of identical construction to form a top frame.
Other objects and features of the present disclosure will be in part apparent and in part pointed out herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a top frame;

FIG. 2 is a perspective of a first top frame member of the top frame seen from an interior side vantage;

FIG. 3 is an elevation view of the first top frame member from an interior side vantage;

FIG. 4 is an enlarged, fragmentary perspective of the first top frame member showing a connection system;

FIG. 5 is a section taken in the plane including line 5-5 of FIG. 4 ;

FIG. 6 is a section similar to FIG. 5 , but taken through the assembled top frame including the first top frame member and a second top frame member;

FIG. 7 is an enlarged, fragmentary perspective of the first top frame member showing a connecting pin;

FIG. 8 a section taken in the plane including line 8-8 of FIG. 7 ;

FIG. 9 is an enlarged, fragmentary perspective of the first top frame member showing a connecting socket;

FIG. 10 is a section taken in the plane including line 10-10 of FIG. 9 ;

FIG. 11 is a section similar to FIG. 10 , but taken through the fully assembled top frame;

FIG. 12 is an enlarged, fragmentary perspective showing another connection feature of the top frame;

FIG. 13 is an enlarged, fragmentary perspective showing another connection feature of the top frame;

FIG. 14 is a section taken in the plane including line 14-14 of FIG. 12 , but showing the fully assembled top frame;

FIG. 15 is an enlarged, fragmentary perspective showing a feature associated with the molding process;

FIG. 16 is a section taken in the plane including line 16-16 of FIG. 15 , but showing the fully assembled top frame;

FIG. 17 is an enlarged, fragmentary perspective showing another feature associated with the molding process;

FIG. 18 is a section taken in the plane including line 18-18 of FIG. 17 , but showing the fully assembled top frame;

FIG. 19 is a perspective of a set of three, stacked top frames;

FIG. 20 is an elevation view of the three, stacked top frames of FIG. 19 ;

FIG. 21 is a partial section taken along line 21-21 of FIG. 20 ;

FIG. 22 is an enlarged detail taken as indicated in FIG. 21 ;

FIG. 23 is a bottom edge elevation of the three, stacked top frames;

FIG. 24 is a partial section taken along line 24-24 of FIG. 20 ; and

FIG. 25 is an enlarged detail taken as indicated in FIG. 24 .

Corresponding reference numbers indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Referring now to the drawings and in particular to FIG. 1 a top frame 10 for use in a pallet system is shown to comprises a frame 12 having a rectangular, picture frame configuration. It will be understood that other configurations fall within the scope of the present invention. In one embodiment, the top frame is sized and shaped in correspondence with a pallet on which articles may be stacked (not shown). The top frame is constructed for placing on top of a stack of articles and more particularly on top of a divider panel (not shown) placed on top of the stack. The top frame includes four elements (10A-10D) which are formed with notches 14 located along an outer peripheral edge of the top frame. In the illustrated embodiment, there are four notches on each element 10A-10D. The notches 14 are sized and arranged to receive respective portions of straps (not shown) wrapped around the pallet, articles, divider panels and top frame. The notches 14 serve as a guide for positioning the straps and help to hold the straps in place. The arrangement and number of notches may be other than shown. Moreover, the notches 14 could be eliminated. The straps would also extend around or be attached to the base pallet (not shown), creating compression between the top frame, the divider panels and the base pallet that operates to increase the lateral stability of the pallet system carrying stacked articles.
The top frame 10 comprises a first top frame member 18 and a second top frame member 20 which are joined together to form the top frame. In the illustrated embodiment, each of the first top frame member 18 and the second top frame member 20 is formed as one piece of material. In some versions, the first and second top frame members 18, 20 are molded from a single piece of polymeric material. Preferably, the first top frame member 18 and the second top frame member 20 are identical in construction (as illustrated herein). As shown, the first top frame member 18 and the second top frame member 20 (as well as the assembled top frame 10) have a rectangular, picture frame shape. It will be understood that other configurations of the first and second top frame members 18, 20 and the top frame 10 may be used. Thus, there is no need to search for a mating pair of top frame members 18, 20. Any two top frame members can be connected together to form a top frame 10.
Referring now to FIGS. 2 and 3 , the first top frame member 18 is shown. It will be understood that because the first and second top frame members 18, 20 are of identical construction, a description of the first top frame member will suffice for a description of the second top frame member. The first top frame member 18 includes a continuous, substantially flat, exterior surface (as shown for the second top frame member 20 in FIG. 1 ), and an interior surface. The interior surface is formed by an inner peripheral wall 22 and an outer peripheral wall 24 connected together by ribbing 26 (see, FIG. 4 ). The ribbing takes the form of a series of rhombi (or “diamonds”) extending between the inner peripheral wall 22 and the inner peripheral wall 24. Adjacent diamonds are connected to each other. In addition, a pair of spaced apart ribs 26 extending lengthwise of each frame element 10A-10D and intersect the diamonds. It will be understood that the ribbing may be arranged in other configurations. The ribbed construction of the interior surface allows the first top frame member 10 to be strong and yet light weight. The continuous, substantially flat exterior surface is desirable for interfacing with the articles, divider panel and/or straps.
The first top frame member 18 includes a plurality of latching connection units 30 (broadly “mechanical connection units”) located on the interior side of the first top frame member. Each latching connection unit 30 includes a male connector element 30A and a female connector element 30B (FIG. 4 ). Referring to FIG. 3 , the bottom element 10B and the top element 10D of the first top frame member 18 each have six latching connection units 30. The latching connection units are located within one of the diamonds of the ribbing 26. Respective ones of the male connector elements 30A and the female connector elements 30B located nearer to the outer peripheral wall 24 of the first top frame member 18 and to the inner peripheral wall 22. The arrangement of the male connector element 30A and the female connector element 30B alternates. In other words, in the first latching connection unit 30 on the left end of the bottom element 10B of the first top frame member 18 as shown in FIG. 3 , the male connector element 30A is located nearer the inner peripheral wall 22 and the female connector element 30B is located nearer the outer peripheral wall 24. Moving to the right, the next latching connection unit 30 has a female connector element 30B nearer to the inner peripheral wall 22 of the bottom element 10B of the first top frame 18, and a male connector element 30A nearer the bottom peripheral wall 24. Further, each latching connection unit 30 of the bottom element 10B is vertically aligned with a latching connection unit of the top element. Each vertically aligned latching connection unit 30 has the same arrangement with respect to the location of the male connector element 30A and the female connector element 30B.
Similarly, the right side element 10A and the left side element 10C of the first top frame member 18 each have four latching connection units 30 spaced along their respective lengths. Some of the latching connection units 30 are located within respective ones of the diamonds formed by the ribbing 26. The position of the male connector element 30A and female connector element 30B alternates from one connection unit 30 to the adjacent connection unit on the right and left side elements 10A, 10C. In the first latching connection unit 30 nearest the bottom on the left element 10C of the first top frame member 18, the male connector element 30A is located nearer to the outer peripheral wall 24 and the female connector element 30B is located nearer the inner peripheral wall 22. Moving upward, the next latching connection unit 30 has a female connector element 30B located nearer the outer peripheral wall 24 of the left element 10C of the first top frame member 18, and the male connector element 30A is located nearer the inner peripheral wall 22. Further, each latching connection unit 30 of the left element 10C of the first top frame member 18 is horizontally aligned with a latching connection unit of the right element 10A. Each horizontally aligned latching connection unit 30 has the inverse arrangement with respect to the location of the male connector element 30A and the female connector element 30B.
Referring now to FIGS. 4-6 , the male connector element 30A projects up from the first top frame member 18 and includes an enlarged head 32 defining a downward (as oriented in FIG. 5 ) facing shoulder 34. The female connector element 30B comprises an arch member 36 having an opening 38, and a retainer member 40. The arch member 36 includes a ramp surface 42 engageable with a corresponding ramp surface 44 on the male connector element 30A to deflect the male connector element 30A so that the enlarged head 32 may pass the upper end of the arch member 36 when the first top frame member 18 and second top frame member 20 are pushed together to form the top frame 10. The retainer member 40 has a ramped surface 46 that engages a back side to engage a back side of the male connector member 30A to drive it toward the arch member 36. Once the rearward facing shoulder 38 reaches the opening 38, the male connector member 30A snaps into the opening so that the rearward facing shoulder is received in the opening and engages the retainer. The retainer member 40 resists dislodgement of the head 32 of the male connector member 30A from the opening 38 of the arch member 36. In this way a secure connection of the first top frame member 18 with the second top frame member 20 is achieved. All of the connection units 30 are constructed and operate in this manner in the illustrated embodiment.
The corners of the interior face of the first top frame member 18 are formed with a pin 48 (see, FIG. 7 ), or a socket 50 (see, FIG. 9 ). Referring to FIG. 3 , the pins 48 are located in the corners of the first top frame member 18 on the right side of the drawings. The sockets 50 are located in the corners of the top frame member 18 on the left side of the drawing. The pins 48 are formed with crush ribs 52. The diameter of each pin 48 measured through the crush ribs 52 is slightly greater than the diameter of the main portion 54 of the hole in the socket 50 (FIG. 10 ). As a result, when the pins 48 are received in the main portions 54 of their respective sockets 50, the ribs 52 are crushed or deformed to produce an interference fit between the pin and the socket (see, FIG. 11 ). Thus, the pin 48 cannot be readily withdrawn from the socket 50 and thereby firmly holds the first top frame member 18 and the second top frame member 20 together. The pin 48 and socket 50 provide another mechanical connection of the first top frame member 18 to the second top frame member 20.
Another alignment feature of the top frame 10 is shown in FIGS. 12-14 . One part of the first top frame member 18 includes a boss 56 and a pull ring 58. The boss 56 is configured to mate with a socket 60 of the second frame member 20. The socket 60 is shown in FIG. 13 , and has a central opening that flares outward near the open end of the socket to facilitate guiding the boss 56 into the socket. When the first top frame member 18 and second top frame member 20 are brought together, the boss 56 is received in the socket 60. The pull ring 58 is a feature associated with molding the top frame 10, and is trimmed back after molding to avoid interference with the fit of the boss 56 in the socket 60, as may be seen in FIG. 14 .
FIG. 15 shows a segment of the first top frame member 18 in which the ribbing 26 includes a curved section 26A. The segment further includes a puck 62 adjacent to the curved section 26A. The puck 62 is a feature of the molding process. This segment mates together with another segment from the second top frame element 20, as shown in FIG. 16 . Another segment of the first top frame member 18 is shown in FIG. 17 that is received on a corresponding segment of the second top frame member as shown in FIG. 18 . The ring shown in FIG. 18 is a feature of the molding process used to keep the frame member engaged to an ejector pin of the mold (not shown) so that the part does not fall out of the mold when it is opened.
As previously stated, the second top frame member 20 is of identical construction. Looking again at FIG. 3 , the second top frame member 20 can be readily positioned for attachment to the first top frame member 18. More specifically, a second top frame member 20 in the same initial orientation shown for the first top frame member in FIG. 3 can be rotated 180° about a vertical axis so that the flat exterior surface of the second top frame member faces out of the page. The second top frame member 20 can then be moved into alignment over the first top frame member 18. The inverted and aligned second top frame member 20 will present the latching connection units 30 that are aligned with corresponding latching connection units 30 of the first top frame member 18. Moreover, for each aligned pair of latching connection units 30, the male connector element 30A of the second top frame member 20 will be aligned with a female connector element 30B of the first top frame member 18. A female connector element 30B of the second top frame member 20 will be aligned with a male connector element 30A of the first top frame member 18. Accordingly, when the first and second frame members 18, 20 are brought together each latching connection unit of the second top frame member snaps into locking engagement with the latching connection unit of the first top frame member. This arrangement can be seen in FIG. 6 , which shows a latching connection unit of the second top frame member lockingly engaged with the latching connection unit of the first top frame member. It will be understood that other connection features, including the pins 48 and sockets 50 of FIGS. 7-9 , and bosses 56 and sockets 60 are also arranged to mate when the second top frame member 20 is positioned for attachment to the first top frame member 18 as described above.
Referring now to FIGS. 19-25 , it may be seen that multiple (e.g., three) top frames can be stacked together in a way in which the top frames are interconnected by stacking structure so that the stacked top frames 10 act mechanically as a single piece. As shown in FIGS. 19 and 20 , each corner of an exterior surface of the top frame 10 has stacking structure including a raised a peg 68 and an adjacent recess 70. The top frames 10 can be stacked so that the pegs 68 of one top frame can be received in the recesses 70 of the adjacent top frame so that the stacked frames have lateral connectivity. Straps (not shown) are applied over the top of the stack of top frames as used on top of items arranged on a pallet to stabilize the items. The straps also hold the stack of top frames together in a vertical direction.
When introducing elements of aspects of the invention or the embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
Not all of the depicted components illustrated or described may be required. In addition, some implementations and embodiments may include additional components. Variations in the arrangement and type of the components may be made without departing from the spirit or scope of the claims as set forth herein. Additional, different or fewer components may be provided and components may be combined. Alternatively, or in addition, a component may be implemented by several components.
The above description illustrates the aspects of the invention by way of example and not by way of limitation. This description enables one skilled in the art to make and use the aspects of the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the aspects of the invention, including what is presently believed to be the best mode of carrying out the aspects of the invention. Additionally, it is to be understood that the aspects of the invention are not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The aspects of the invention are capable of other embodiments and of being practiced or carried out in various ways. Also, it will be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
It will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. As various changes could be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
The Abstract and Summary are provided to help the reader quickly ascertain the nature of the technical disclosure. They are submitted with the understanding that they will not be used to interpret or limit the scope or meaning of the claims. The Summary is provided to introduce a selection of concepts in simplified form that are further described in the Detailed Description. The Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the claimed subject matter.

Claims

What is claimed is:

1. A top frame for use in a pallet assembly to stabilize articles held on a pallet, the top frame comprising:

a first top frame member including first mechanical connection units;

a second top frame member including second mechanical connection units, the second top frame member being configured to be secured to the first top frame member with the first mechanical connection units connected to the second mechanical connection units.

2. The top frame as set forth in claim 1 wherein the first and second mechanical connection units are configured for snap together mating.

3. The top frame as set forth in claim 2 wherein each of the first and second mechanical connection units comprises a male connector element and a female connector element, the male connector element of the first mechanical connection unit being engaged with the female connector element of the second mechanical connection unit, and the female element of the first mechanical connection unit being engaged with the male connector element of the second mechanical connection unit.

4. The top frame as set forth in claim 2 wherein the first top frame member and the second top frame member are each formed as one piece of material.

5. The top frame as set forth in claim 4 wherein each of the first top frame member and the second top frame member are molded from a polymeric material.

6. The top frame as set forth in claim 5 wherein the first top frame member and the second top frame member have the identical construction.

7. The top frame as set forth in claim 6 wherein the first and second mechanical connection units each have a rectangular, picture-frame shape.

8. The top frame as set forth in claim 7 wherein each of the first top frame member and the second top frame member has an exterior surface including a flat surface and an interior surface formed by ribbing.

9. The top frame as set forth in claim 8 wherein the first and second top frame members are free of welded interconnection.

10. The top frame as set forth in claim 1 wherein the first top frame member and the second top frame member are each formed as one piece of material.

11. The top frame as set forth in claim 1 wherein each of the first top frame member and second top frame member are formed with stacking structure for interconnection with another top frame of the same construction.

12. The top frame as set forth in claim 1 wherein the first top frame member and the second top frame member have the identical construction.

13. The top frame as set forth in claim 1 wherein the first top frame member includes a pin having at least one axially extending rib, and the second top frame member includes a socket receiving the pin, the rib of the pin and the socket being engaged in an interference fit.

14. The top frame as set forth in claim 1 wherein each of the first top frame member and the second top frame member has an exterior surface including a substantially flat surface and an interior surface formed by ribbing.

15. The top frame as set forth in claim 1 wherein the first and second top frame members are free of welded interconnection.

16. The top frame as set forth in claim 1 wherein the first and second top frame members including aligned channels for receiving strapping applied to the pallet, articles held by the pallet and the top frame.

17. A top frame member for use in forming a top frame configured for use in a pallet assembly to stabilize articles held on a pallet, the top frame member comprising:

a generally rectangular frame having an exterior including a flat surface, an interior including ribbing supporting the flat surface;

mechanical connections arranged around the frame are configured for snap together mating with mechanical connections of another top frame member of identical construction to form a top frame.

18. The top frame member as set forth in claim 16 wherein the top frame member is formed as a single piece of material.

19. The top frame member as set forth in claim 16 wherein the top frame member is molded from a polymeric material.

20. The top frame as set forth in claim 16 wherein the top frame member is formed with stacking structure for interconnection with another top frame of the same construction.