Metal Pallet

Abstract

A lightweight, high-strength metal pallet is provided that includes a deck and a plurality of runners. Each one of the runners includes either a box-like skin and cellular support members disposed therein or a vertical web disposed within the cellular support members. The deck may also be formed of plywood or similar material. The cellular support members are oriented substantially vertically within the runner skin, and preferably form hex-cells, such that the pallet may withstand some crushing or other damage without catastrophic failure. Preferably, the deck, the skins or the webs and the support members are formed of ungalvanized steel to enable the steel pallet to be disposed in a steel remelt furnace after a single service, such as shipping refractory bricks to a steel manufacturing facility. The pallet may be formed of coated or galvanized steel for re-use. Pallets formed of other metals are also disclosed.

1 . A metal pallet comprising: 
 a deck, formed of a material comprising a metal, having a top surface and a bottom surface; and    a plurality of runners formed of a material comprising a metal and coupled to the bottom surface of the deck, each one of the plurality of runners including: 
 a skin, formed of a material comprising a metal, having a shape that is substantially box-like; and  
 cellular support members, formed of a material comprising a metal, being coupled to each one of the skin and the deck and disposed substantially vertically and substantially within the runner,  
   whereby the top surface of the pallet is suitable for receiving a cargo thereon and the runner cellular structure enhances the rigidity and strength of the pallet.    
     
     
         2 . The metal pallet of claim I wherein each one of the deck, the skins, and the support members are formed of ungalvanized steel, thereby enabling the steel pallet to be disposed in a steel remelt furnace.  
     
     
         3 . The metal pallet of  claim 1  having a payload to pallet weight ratio of at least 1,000 to 1.  
     
     
         4 . The metal pallet of  claim 3  having a payload to weight ratio of at least 1,300 to 1.  
     
     
         5 . The metal pallet of  claim 1  wherein the deck is formed of a corrugated steel that yields under a static, semi-rigid, compressive load before the before the runners fail under the load.  
     
     
         6 . The metal pallet of  claim 2  wherein the metal pallet is formed of a material that is not the same as the material of the cargo.  
     
     
         7 . The metal pallet of claim I wherein each one of the cellular support members is a vertically-oriented honeycomb disposed within the runner.  
     
     
         8 . The metal pallet of  claim 7  wherein each one of the honeycomb cells includes substantially continuous sides and an open top over which the deck is disposed and an open bottom beneath which a bottom portion of the skin is disposed.  
     
     
         9 . The metal pallet of  claim 8  wherein each one of the honeycomb cells is hexagonal.  
     
     
         10 . The metal pallet of  claim 8  wherein each one of the skins includes a first sidewall, a second sidewall, and a bottom member coupled therebetween.  
     
     
         11 . The metal pallet of  claim 10  wherein bottom member includes a plurality of apertures formed therein to provide access [for inspection, fumigation] to the honeycomb cells.  
     
     
         12 . The metal pallet of  claim 10  wherein the bottom members are substantially parallel to a plane defined by the deck and substantially perpendicular to each one of the first and second sidewalls.  
     
     
         13 . The metal pallet of  claim 10  wherein each longitudinal end of each one of the skins includes end flanges that at least partially retain the honeycomb within the skins.  
     
     
         14 . The metal pallet of  claim 10  wherein the cellular support members are formed by a first ribbon support member and an opposing second ribbon support member, each one of the first and second ribbon support members including an inner portion, an opposing outer portion, and a pair of oblique portions therebetween, the inner portions of the first and second support members being abutted together such that the outer portion of the first ribbon support member opposes the outer member of the second ribbon support member.  
     
     
         15 . The metal pallet of  claim 14  wherein the inner portions of the first and second ribbon support members are affixed together by welding, each one of the ribbon member outer portions and the skin sidewalls are affixed together by welding, and each one of the ribbon members is in contact with the deck bottom surface.  
     
     
         16 . The metal pallet of  claim 10  wherein each one of the skins includes a first flange formed at the top of the first sidewall and a second flange formed at the top of the second sidewall, each one of the first and second flanges being welded to a bottom surface of the deck.  
     
     
         17 . The metal pallet of  claim 16  wherein the deck is formed of corrugated steel such that a trough of the corrugations form the deck bottom surface.  
     
     
         18 . The metal pallet of  claim 17  wherein the deck is substantially continuous thereby facilitating loading of cargo thereon.  
     
     
         19 . The metal pallet of  claim 18  wherein each one of the runners defines a longitudinal centerline that is substantially perpendicular to a direction of the deck corrugations.  
     
     
         20 . The metal pallet of  claim 7  wherein the deck is formed of a corrugated steel, and the plurality of runners includes an inner runner and a pair of outer runners, the skins of each one of the outer runners having an outboard flange extending from an outboard side thereof, each one of the outboard flanges having a channel portion that is disposed over an edge of the deck.  
     
     
         21 . The metal pallet of  claim 20  wherein each one of the channels includes apertures formed on an underside thereof to enhance access to the underside of peak portions of the deck corrugations, whereby the welding together of the peak portions and a top portion of the channels may be facilitated.  
     
     
         22 . The metal pallet of  claim 1  wherein the metal pallet is employed for carrying refractory materials.  
     
     
         23 . The metal pallet of  claim 1  wherein the metal pallet is employed for warehouse rack and shelving applications.  
     
     
         24 . The metal pallet of  claim 1  wherein the metal pallet is employed for food processing applications.  
     
     
         25 . A pallet comprising: 
 a deck having a top surface and a bottom surface; and    a plurality of steel runners coupled to the bottom surface of the deck, each one of the plurality of runners including: 
 a substantially vertical support disposed below the deck;  
 steel honeycomb support members coupled to the vertical support; and  
 a foot pad being disposed below the support members and the vertical support;  
   whereby the top surface of the pallet is suitable for receiving a cargo thereon and the runner cellular structure enhances the rigidity and strength of the pallet.    
     
     
         26 . The pallet of  claim 25  wherein the vertical support comprises a steel skin having a rectangular shape in transverse cross section and a pair of flanges extending outwardly therefrom, the skin being longitudinally oriented relative to the deck, the honeycomb support members being disposed substantially vertically within the skin, a bottom portion of the skin integrally forming the footpad.  
     
     
         27 . The pallet of  claim 26  having a payload to pallet weight ratio of at least 1,300 to 1.  
     
     
         28 . The pallet of  claim 26  wherein the deck is formed of corrugated steel.  
     
     
         29 . The pallet of  claim 28  wherein the corrugations of the deck yield under a static, semi-rigid, compressive load before the before the runners fail under the load.  
     
     
         30 . The pallet of  claim 26  wherein the deck is formed of a wooden sheet.  
     
     
         31 . The pallet of  claim 26  wherein the plurality of runners is galvanized, whereby the pallet is designed for multiple uses.  
     
     
         32 . The pallet of  claim 26  wherein the plurality of runners is uncoated steel, whereby the steel is in condition for recycling.  
     
     
         33 . The pallet of  claim 25  wherein the vertical support comprises a web disposed, the honeycomb support formed by a pair of opposing ribbon support members, the web being disposed between the ribbon support members.  
     
     
         34 . The pallet of  claim 33  wherein the deck is formed of corrugated steel.  
     
     
         35 . The pallet of  claim 34  having a payload to pallet weight ratio of at least 1,300 to 1.  
     
     
         36 . The pallet of  claim 35  wherein the corrugations of the deck fail under a static, semi-rigid, compressive load before the before the runners fail under the load.  
     
     
         37 . The pallet of  claim 34  wherein the deck is formed of a wooden sheet.  
     
     
         38 . The pallet of  claim 34  wherein the plurality of runners is galvanized, whereby the pallet is designed for multiple uses.  
     
     
         39 . The pallet of  claim 34  wherein the plurality of runners is uncoated steel, whereby the steel is in condition for recycling.  
     
     
         40 . A method of processing a pallet capable of carrying various useful cargo, comprising the steps of: 
 receiving cargo on the pallet that is formed of ungalvanized steel and lightweight,the cargo consisting of a product that is not ungalvanized steel;    unloading the cargo from the pallet; and    disposing the pallet in a steel remelt furnace for melting of the pallet, whereby the melted pallet is suitable for making recycled steel.    
     
     
         41 . The method of claim  40  wherein the receiving step includes receiving the cargo on the pallet that includes: 
 a top surface and a bottom surface; and  
 a plurality of runners formed of a material comprising a metal and coupled to the bottom surface of the deck, each one of the plurality of runners including: 
 a skin, formed of a material comprising a metal, having a shape that is substantially box like; and  
 cellular support members, formed of a material comprising a metal, being coupled to each one of the skin and the deck and disposed substantially vertically and substantially within the runner,  
 
 whereby the top surface of the pallet is suitable for receiving the cargo thereon and the cell structure enhances the rigidity and strength of the pallet.  
 
     
     
         42 . The method of claim  40  wherein the receiving step includes receiving the cargo on the pallet that includes: 
 a top surface and a bottom surface; and  
 a plurality of runners formed of a material comprising a metal and coupled to the bottom surface of the deck, each one of the plurality of runners including: 
 a web, formed of a material comprising metal;  
 cellular support members, formed of a material comprising a metal, being coupled to each one of the web and the deck and disposed substantially, the web being disposed substantially vertically within the cellular support members, and  
 a footpad disposed below the cellular support members;  
 
 whereby the top surface of the pallet is suitable for receiving the cargo thereon and the cell structure enhances the rigidity and strength of the pallet.  
 
     
     
         43 . The method of claim  42  wherein the disposing step includes disposing the pallet in the steel remelt furnace upon its first service or after the pallet has sustained damage to make it unfit for further service.