Description:FIELD OF INVENTION

The present invention concerns pallets for transporting machined semi-finished/finished component/s and or assemblies thereof. In particular, the present invention relates to a wood-free, strong pallet having low-maintenance and/or repair cost for transporting semi-finished/finished component/s and or assemblies thereof. More particularly, the present invention relates to a sustainable, wood-free box-type polypropylene pallet assembly for transporting semi-finished/finished component/s and or assemblies thereof, e.g., in an automobile manufacturing plant.

BACKGROUND OF THE INVENTION

There are different types of pallets (Figures 1a-1d) available in the market for packing of items, e.g. cardboard pallets, which are not suitable for storing/loading heavy components thereon; or plastic pallets, which cause slippage of components stored/loaded thereon and also prone to cracks; or pressed wooden pallets, which are also not capable of storing/loading of heavy components thereon; and metal pallets, which easily damage the machined components stored/loaded thereon.

The automobiles and farm equipment manufacturing units/plants at various locations manufacture finished products and/or components/sub-assemblies thereof at different locations. These products, components and/or sub-assemblies are required to be transported to units/plants away from their manufacturing unit/plant for further processing and/or assembly to obtain final products.

Generally, heavy components/sub-assemblies, (e.g., transmission housings, crankcases, cylinder heads, differential cases and clutch housings, and different sheet metal parts etc.) when transported over long distances are normally packed in Mild steel (MS) structure and wood. Each of these pallet weighs about 70-75 kg, which are handled by store employees, manufacturing department, as well as transporters.

However, these wooden pallets have the following disadvantages:

• Loaded Wooden pallets get damaged during transport and transit thereof.

• In a typical manufacturing unit/plant, out of 40-50 loaded pallets received, 5-10 wooden pallets need repairs on daily basis.

• Often wooden pallets fall short of the required number for Inter Unit Transfer (IUTN).

• Moreover, on an average, 15 ton of wooden plank waste is generated from above wooden pallet repairs.

• During the wooden pallets repair, accidents and injuries are common.

• The above wooden pallet repair cost is approximately INR 30 Lacs / annum.

Therefore, the pallets for storing/loading heavy components thereon should fulfill the following requirements:

• The pallet maintenance should be zero.

• Suitable alternatives for wooden pallets should be explored.

• The design of pallets should be made robust and sturdy during frequent transport and transit thereof.
• The alternative design of pallets should be slippage-proof.

Accordingly, a comparative analysis of different alternative pallets to be used in place of wooden pallets in manufacturing plants/units was carried out, the results of which are tabulated below:

Material / shape Load Strength Dura-bility Repair- cost Operational safety Suitability for machining components
Frame L-shaped MS strips Low Moderate Low High Moderate Suitable
Box-type High High High Low High Suitable
Base support Polypropylene sheet High High High Low Moderate Suitable
Wood Moderate High Low High Low Suitable
Metal plate High High High Low Low Not suitable

DESCRIPTION OF THE INVENTION

Based on the above comparative analysis of alternative material for wooden pallets, the box-type frame is selected by the inventors for imparting more strength to the pallets and polypropylene sheet with anti-skid rubber sheet is selected to be used for imparting an anti-skid property to the pallets during uses thereof during transport/storage and transit of heavy components/sub-assemblies thereon.

Therefore, a sturdy square box-type frame is selected to be used instead of L-shaped channels to impart more strength to the newly configured pallets for transport/storage and transit of heavy components. Moreover, from the sustainability point of view, polypropylene sheet is selected instead of wooden planks for making these pallets.
Additional safety is ensured by using anti-skid rubber to prevent slipping of heavy components/sub-assemblies stored/transported on these newly configured pallets.

Further, a comparison of the costs of the wooden pallets with the polypropylene (PP) pallet is also conducted before deciding the configuration of the selected pallet for storing/transporting and transit of heavy components/sub-assemblies:

Parameter Wooden pallet PP pallet Remark
Pallet configuration:
Wood Yes
(Jungle wood) No PP and anti-skid base used.
Life 2.5 year 10 years New pallet life is 10 years.
Pallet price INR 5700 INR 19179 Higher initial cost but low-operational cost.
Structure Angle structures (Weak) Box-structure
(Very strong) Strong base structure.
Pallet maintenance:
Repair frequency Every alternate year. NBR replacement after 4 years.
Pallet repair cost INR 2500. INR 500.
Pallet repair cost/pallet after 6 years. INR 7500. INR 750.

Therefore, the present invention concerns pallets for transporting machined semi-finished/finished component/s and or assemblies thereof over long distances. The present invention concerns wood-free, strong pallets having low-maintenance and/or repair cost for transporting semi-finished/finished component/s and or assemblies within different unit within and/or between different manufacturing plants/units.
The present invention also concerns sustainable, wood-free box-type polypropylene pallet for transporting semi-finished/finished component/s and or assemblies within different units within a manufacturing plant and/or between different manufacturing plants, e.g. automobile manufacturing plants.

Although these pallets configured in accordance with the present invention cost higher, their operational cost is very low and their life is four times that of the conventional wooden pallets. These newly configured pallets not only offer durability but also eliminate the use of wood to encourage sustainable manufacturing process.

To summarize, these pallets show substantial tangible and intangible benefits over the conventional wooden pallets, as indicated below:

Tangible benefits
For 170 Nos. of Experimental pallets: For 10100 Nos. proposed for use:
Wood saving: 14 ton 750 Ton
Pallet repair cost-saving: INR 3.5 Lakh. INR 200 Lakh.
Wood elimination/pallet 75 kg
Repair cost/saving/pallet INR 2000.
Intangible benefits
• Follow-up for Inter Unit Transfer (IUTN) pallet checking and repairing is Zero.
• First Time Right (FTR) is achieved.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An object of the present invention is to provide multipurpose polypropylene box-pallets for storage/transport of machined components and/or sub-assemblies.

Another object of the present invention is to provide an improved and operationally safe polypropylene box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies.

Still another object of the present invention is to provide a wood-free, thus sustainable, polypropylene box-pallets for storage/transport of machined components and/or sub-assemblies.

Yet another object of the present invention is to provide stronger, polypropylene box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies.

A further object of the present invention is to provide low-repair/maintenance polypropylene box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies.

A still further object of the present invention is to provide durable, polypropylene box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies.

These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.
SUMMARY OF INVENTION

In accordance with the present invention, there is provided a sustainable, multipurpose polypropylene (PP) box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies, the PP box-pallet assembly comprises:

(a) a base frame made of metal;

(b) at least one polypropylene (PP) sheet disposed on top and bottom face of the base frame;

(c) a plurality of T-slots configured in the PP sheets; and

(d) a plurality of profiled rubber strips/gaskets to be fixed in each of the T-slots by sliding therein for imparting an anti-skid surface to said box-pallet assembly.

Typically, the base frame is made of hollow square mild steel (MS) pipes connected to each other through L-angles by means of fasteners.

Typically, the hollow square mild steel (MS) pipes are made by bending of 5 mm thick metal sheet into a 30 mm square cross-section.

Typically, the PP sheet comprises a thickness of at least 15 mm.

Typically, the straight T-slots are made in the PP sheet by machining.

Typically, the straight T-slot comprises a flange portion having a predefined thickness and a profiled web portion having a predefined height.

Typically, the profiled web portion comprises a serrated or knurled end protruding out of the PP sheet for imparting anti-skidding property thereto.

Typically, the profiled web portion comprises about 50% of the height thereof embedded in the PP sheet and the remaining 50% of the height thereof is protruding above the PP sheet outer surface.

Typically, the rubber strips are made of Nitrile rubber for imparting the anti-skid property to the PP sheet surfaces when loaded/stored with the heavy components/sub-assemblies.

In accordance with the present invention, there is also provided a sustainable, multipurpose polypropylene box-pallets with anti-skid support for storage/transport of machined components and/or sub-assemblies, comprising:

(i) a base frame consisting of square pipes of a predetermined number and lengths;

(ii) a pair of L-angles for connecting the square pipes for assembling the base frame;

(iii) a predetermined number of profiled Nitrile rubber strips/gaskets fitted in a corresponding number of T-slots;

(iv) a respective top and bottom plate made of PP sheet and side plates;

wherein the PP box pallets assembly is assembled by using a plurality of fasteners for connecting the square pipes of the base frame and applying a suitable glue/adhesive for fitting/joining the Nitrile rubber strips/gaskets in the T-slots machined in the PP sheets for imparting an anti-skid surface thereto and two opposed sides of the base frame is left as two-way open guide for using the PP box pallet assembly by material handling equipment for loading/storing the heavy components thereon or unloading the heavy components therefrom.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described in the following with reference to the accompanying drawings.

Figure 1 shows a typical movement of the pallets loaded with heavy components from one manufacturing plant to another and then to yet another plant.

Figures 2a-2e show different types of conventional pallets available.

Figure 3a show an undamaged wooden pallet before loading thereof with heavy components.

Figures 3b-3c show the condition of the deshaped wooden pallet after loading with heavy components.

Figure 3d shows a wooden pallet damaged during transport and transit between different manufacturing units / plants.

Figure 3e shows the wooden planks required for repairing of damaged/deshaped wooden pallets.

Figure 3f shows the waste pieces of wooden planks used during the repair of damaged wooden pallets
Figure 4 shows an exploded view of the sustainable, multipurpose polypropylene box-pallets assembly with anti-skid support configured for storage/transport of machined components and/or sub-assemblies.

Figure 5 shows an assembled view of the polypropylene box-pallets with anti-skid support of Figure 4.

Figure 6a shows the mild steel (MS) base frame of the polypropylene box-pallet assembly of Figure 5 without anti-skid rubber support placed thereon.

Figure 6b shows the top and side views of polypropylene sheet to be fitted in T-slots of box-pallet assembly of Fig. 5 for providing anti-skid support therein.

Figure 7 shows a perspective view of the sustainable, multipurpose polypropylene box-pallets with anti-skid rubber support for storage/transport of machined components and/or sub-assemblies thereon.

Figures 8a-8c respectively show top and side views of the sustainable, multipurpose polypropylene box-pallets with anti-skid rubber support for storage/transport of machined components and/or sub-assemblies thereon.

Figures 9a-9b show the T-slot machined in the polypropylene (PP) sheet for fixing anti-skid rubber support in the sustainable, multipurpose polypropylene box-pallets for storage/transport of machined components and/or sub-assemblies thereon.

Figure 10 shows the use of the sustainable, multipurpose polypropylene box-pallets with anti-skid rubber support for storage/transport of different heavy machined components and/or sub-assemblies thereon.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, sustainable, multipurpose polypropylene box-pallets with anti-skid support configured in accordance with the present invention will be described in more detail with reference to the accompanying drawings without limiting the scope and ambit of the present invention.

Figure 1 shows typical transfer of an empty pallet EP from plant M1 to be loaded with one or more heavy components, e.g., crankcase/s at plant M2 to be transferred to another manufacturing plant M3 and to be unloaded there for further processing. This empty pallet EP is now returned to plant M2 and subsequently loaded with another set of machined heavy components at that plant M2 to be transferred back to the manufacturing plant M1 to be unloaded there for further processing.

Figure 2a shows a conventional cardboard pallet available in the market, which is not suitable for storing/loading heavy cast and/or machined components, like crankcases, cylinder heads and transmission housings etc.

Figure 2b shows a plastic pallet available in the market, which has the disadvantage of slippage of the heavy components stored thereon.

Figure 2c shows a pallet made of pressed wood available in the market, which is also not suitable for storing/loading heavy cast and/or machined components, like crankcases, cylinder heads and transmission housings etc.

Figure 2d shows a metal pallet available in the market, which is not suitable for storing/loading heavy cast and/or machined components because of the damage caused due to metallic surfaces thereof.
Figure 2e shows a conventional plastic pallet PP available in the market, however it also has the disadvantage of getting warped/bent on loading of heavy components thereon.

Figure 3a shows an undamaged empty wooden pallet EWP before loading thereof with heavy components.

Figure 3b shows the condition of the deshaped wooden pallet WP after loading with heavy components HC thereon.

Figure 3c shows the condition of the deshaped wooden pallet WP loading with heavy components HC thereon.

Figure 3d shows a wooden pallet damaged DWP during transport and transit between different manufacturing units / plants.

Figure 3e shows the wooden planks Pk required for repairing of damaged/deshaped wooden pallets WP.

Figure 3f shows the waste pieces of wooden planks WWP used during the repair of damaged wooden pallets WP.

Figure 4 shows an exploded view of the sustainable, multipurpose polypropylene box-pallets WP assembly 100 configured with anti-skid support in accordance with the present invention, for storage/transport of machined components and/or sub-assemblies. The box-pallet includes a base frame 10, e.g., made of 30 mm square mild steel pipes (e.g., made of 5 mm thick metal sheet), which are strong enough to load up to 10 ton. This frame 10 is covered on both sides (top and bottom) by a respective polypropylene sheet 20 of predefined thickness (e.g., 15 mm thick) provided with a plurality of T-slots 22 for fixing of a plurality of rubber strips (e.g., made of Nitrile rubber) 24 for imparting the box-pallet an anti-skid property when loaded/stored with heavy components/sub-assemblies, like crankcases, transmission housing, cylinder heads etc. The Nitrile rubber is known for its good machinability even at high temperatures. The PP sheet 20 is machined with T-slots 22 for imparting a strong grip for Nitrile rubber strip 24 inserted therein.

Figure 5 shows an assembled view of the polypropylene box-pallets PP with anti-skid support of Figures 3a-3c.

Figure 6a shows the base frame of the polypropylene box-pallet assembly 100 of Figure 5 without the anti-skid rubber support placed thereon.

Figure 6b shows the top view the polypropylene sheet to be fitted in T-slots of the box-pallet assembly 100 of Figure 5 for providing an anti-skid support therein.

Figure 7 shows a perspective view of the sustainable, multipurpose assembly 100 of polypropylene box-pallet with anti-skid rubber support configured in accordance with the present invention, for storage/transport of machined components and/or sub-assemblies thereon. This box-pallet assembly includes a base frame 10 consisting of square pipes 102, 104, 106, 108, 110 of different lengths and numbers. These square pipes are connected via L-angles 116 and 118. Nitrile rubber gaskets 120 are fitted in T-slots 22 configured on the polypropylene sheets for imparting anti-skid properties to this box pallet assembly. A plurality of bottom plates 122 and side plates 124 as well as fasteners are used for assembling the overall assembly and a suitable glue/adhesive is used for joining rubber gaskets 120 in T-slots 22 of the box-pallet assembly.

Figure 8a shows top view of the sustainable, multipurpose polypropylene box-pallet assembly 100 of Figure 7. Here, square pipes 108, 110 (8 nos. each), and bottom plate 122 (4 nos.), and side plates 124 (2 nos.).

Figure 8b shows a first side view of the polypropylene box-pallets assembly 100 of Figure 7. Here, square pipes 104 (4 nos.) and 106 (24 nos.), and side plates 124 (2 nos.) are clearly visible.

Figure 8c shows a second side view of the polypropylene box-pallets assembly 100 of Figure 7. Here, square pipes 102 (10 nos.), 112 (8 nos.), L-angle 116 (4 nos.), 118 (4 nos.), and bottom plates 122 (4 nos.) are clearly visible.

Figure 9a shows the T-slot 22 machined in the polypropylene (PP) sheet 20 for fixing anti-skid rubber strip 24 (Figure 9b) in the polypropylene box-pallet for supporting the machined components and/or sub-assemblies during the storage/transport thereof. The slot 22 has a flange portion Tf (e.g., 20.5 mm wide) of thickness Ft and a web portion Tw (e.g., 16 mm wide) of predefined height (e.g., 8 mm, 4 mm projected from PP Sheet and 4 mm inside PP sheet).

Figure 9b shows the anti-skid rubber strip 24 fixed in the T-slot 22 machined in the polypropylene (PP) sheet 20 for supporting the machined components and/or sub-assemblies during the storage/transport thereof.

Figure 10 shows the use of the sustainable, multipurpose polypropylene box-pallet assembly 100 with anti-skid rubber support configured in accordance with the present invention, for storage/transport of different heavy machined components HC and/or sub-assemblies thereon.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The sustainable, multipurpose wood-free polypropylene box-pallet assembly configured in accordance with the present invention for transporting/storing machined components/sub-assemblies offers the following advantages:

• Eliminates 750 ton of wood consumed over a period of 7-8 years, thus saving 1000 trees from being cut for conventional wooden pallets.

• Saves wooden pallet repairing cost of about INR 30 Lakh per year.

• Reduces carbon footprint by about 15 ton.

• Safer as compared to conventional wooden pallets.

• Substantially higher lifespan of 10 years, 4 times the wooden pallets.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to imply including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.

The description of the exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top”, and “bottom” as well as derivatives thereof (e.g., “horizontally”, “inwardly”, “outwardly”; “downwardly”, “upwardly” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion.

These relative terms are for convenience of description and do not require that the corresponding apparatus or device be constructed or operated in a particular orientation.

List of Reference Numerals

100 Sustainable, multipurpose PP box-pallets WP assembly
10 Base frame
20, Polypropylene (PP) sheet
22 T-slot
24 Rubber strip/gasket

102,104, Square pipes
106,108,110

116, 118 L-angles
120 Nitrile rubber strips/gaskets fitted in T-slots
122 Bottom plates
124 Side plates

M1,M2,M3 Manufacturing plants
EP Empty pallet
PP Conventional plastic pallet available in the market
WP Wooden pallet
EWP Empty wooden pallet before loading with heavy components.
HC Heavy components
DWP Wooden pallet damaged by transport/transit between plants
Plk Wooden planks Pk for repairing of DWP
WWP Waste pieces of wooden planks for repairing DWP
Tf Flange of T-slot
Ft Flange thickness
Tw Web portion , Claims:We claim:

1. A sustainable, multipurpose wood-free polypropylene (PP) box-pallet assembly (100) with anti-skid support for storing/transporting heavy components/sub-assemblies, said PP box-pallet assembly (100) comprises:

(a) a base frame (10) made of metal;

(b) at least one polypropylene (PP) sheet (20) disposed on top and bottom face of said base frame (10);

(c) a plurality of T-slots (22) configured in said PP sheets (20); and

(d) a plurality of profiled rubber strips/gaskets (24) fixed in each of said T-slots (22) by sliding therein for imparting an anti-skid surface to said box-pallet assembly.

2. The PP box pallet assembly (100) as claimed in claim 1, wherein said base frame (10) is made of hollow square mild steel (MS) pipes connected to each other through L-angles by means of fasteners.

3. The PP box pallet assembly (100) as claimed in claim 2, wherein said hollow square mild steel (MS) pipes are made by bending of 5 mm thick metal sheet into a 30 mm square cross-section.

4. The PP box pallet assembly (100) as claimed in claim 1, wherein said PP sheet (20) comprises a thickness of at least 15 mm.

5. The PP box pallet assembly (100) as claimed in claim 1, wherein said T-slots (22) are straight and made in said PP sheet (20) by machining.

6. The PP box pallet assembly (100) as claimed in claim 5, wherein said T-slot (22) comprises a flange portion (Tf) having a thickness (Ft) and a profiled web portion (Tw) having a predefined height.

7. The PP box pallet assembly (100) as claimed in claim 6, wherein said profiled web portion (Tw) comprises a serrated or knurled end protruding out of said PP sheet (20) for imparting anti-skidding property thereto.

8. The PP box pallet assembly (100) as claimed in claim 6, wherein said profiled web portion (Tw) comprises about 50% of the height thereof embedded in said PP sheet (20) and the remaining 50% of the height thereof is protruding above said PP sheet (20) outer surface.

9. The PP box pallet assembly (100) as claimed in claim 1, wherein said rubber strips (24) are made of Nitrile rubber for imparting said anti-skid property to the PP sheet (20) surfaces when loaded/stored with said heavy components/sub-assemblies.

10. The PP box pallet assembly (100) as claimed in claim 1, wherein said PP box pallet assembly comprises:

(i) a base frame (10) consisting of square pipes (102, 104, 106, 108, 110) of a predetermined number and lengths;

(ii) a pair of L-angles (116, 118) for connecting said square pipes (102, 104, 106, 108, 110) for assembling said base frame (110);

(iii) a predetermined number of profiled Nitrile rubber strips/gaskets (120) fitted in a corresponding number of T-slots (22);

(iv) a respective top and bottom plate (122) made of PP sheet (20) and side plates (124);

wherein said PP box pallets assembly (100) is assembled by using a plurality of fasteners for connecting the square pipes (102, 104, 106, 108, 110) of said base frame (10) and applying a glue/adhesive for fitting/joining said Nitrile rubber strips/gaskets (120) in said T-slots (22) machined in said PP sheets (20) for imparting an anti-skid surface thereto and two opposed sides of said base frame (10) is left as two-way open guide for using said PP box pallet assembly by material handling equipment for loading/storing said heavy components thereon or unloading said heavy components therefrom.

Dated this 15th day of November 2023.

Digitally / e-Signed by:

(SANJAY KESHARWANI)
APPLICANT’S PATENT AGENT
REGN. NO. IN/PA-2043.