High density pallet system

Abstract

A pallet system for shipping a number of spools includes a pad which supports and retains a first layer of spools. A separator is disposed atop the first layer of spools and a second layer of spools is disposed atop the separator. Subsequent layers of spools and separators may be included in a stacked relationship, and a cap member is disposed atop the topmost layer of spools. The pad, cap, and separators form a stacked shipping unit and may include locking features and provisions for retaining straps.

1 . A pallet system for retaining a plurality of spools, each spool including a core having a filamentary material wound thereabout, said system comprising:
 a pad having a first face configured to rest upon a support surface and a second face having a plurality of spool-engaging features defined thereupon, each spool-engaging feature being configured and operable to engage a spool so that said pad is capable of supporting a layer of said spools on said second face in a predetermined pattern;   at least one separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-engaging features being disposed in said predetermined pattern;   a cap having a first face having a plurality of spool-engaging features defined upon said first face thereof, said spool-engaging features being disposed and operable so as to engage said spools in said predetermined pattern;   wherein said pad, said at least one separator, and said cap are configured and operable so that in the use of said system, said second surface of said pad can receive and support a first layer of spools thereupon in said predetermined pattern, and the spool-engaging features of a first one of said at least one separator engage said first layer of spools, and wherein a second layer of spools may be supported on the second face of said one of said at least one separators; and wherein said spool-engaging features of said cap can engage a layer of spools supported on either the second face of said first one of said at least one separators, or on a second face of another one of said at least one separators.   
     
     
         2 . The pallet system of  claim 1 , wherein the spool-engaging features of at least one of said pad, said at least one separator, and said cap are each configured to project into the core of a spool. 
     
     
         3 . The pallet system of  claim 2 , wherein said spool-engaging features which are each configured to project into the core of a spool comprise conical features. 
     
     
         4 . The pallet system of  claim 1 , wherein the spool-engaging features of at least one of: said pad, said at least one separator, and said cap are each configured so as to engage a spool and permit a portion of the length of the core of said spool to project thereinto. 
     
     
         5 . The pallet system of  claim 1 , wherein said spool-engaging features which are each configured to permit a portion of the length of the core of said spool to project thereinto comprise openings defined in a respective one of said pad, said at least one separator, and said cap. 
     
     
         6 . The system of  claim 1 , wherein said pad, said at least one separator, and said cap are formed from a polymeric material. 
     
     
         7 . The system of  claim 6 , wherein said polymeric material is a thermoformed polymeric material. 
     
     
         8 . The system of  claim 6 , wherein said polymeric material is selected from the group consisting of high molecular weight polyethylene, high-density polyethylene, low-density polyethylene, acrylonitrile-butadiene-styrene, polypropylene, polyethylene, and combinations thereof. 
     
     
         9 . The system of  claim 6 , wherein said polymeric material includes a reinforcing agent therein. 
     
     
         10 . The system of  claim 1 , wherein the first face of said pad is configured to be engageable by a lift fork. 
     
     
         11 . The system of  claim 1 , wherein at least one of said pad, said at least one separator, and said cap include a notch therein configured to engage a binding strap. 
     
     
         12 . The system of  claim 1 , wherein said first face of said pad is further configured so as to be engageable with a second face of said cap which second face is opposite the first face thereof. 
     
     
         13 . The system of  claim 1 , wherein at least one of said pad, said cap, and said separator is configured to be gripped by a robotic lifter. 
     
     
         14 . The system of  claim 1 , wherein said spool-engaging features define a staggered matrix. 
     
     
         15 . A method for packing spools, each spool including a core having a filamentary material wound thereabout, said method comprising:
 (a) providing a pad having a first face configured to rest upon a support surface and a second face having a plurality of spool-engaging features defined thereupon, each spool-engaging feature being configured and operable to engage a spool so that said pad is capable of supporting a layer of said spools on said second face, in a predetermined pattern;   (b) disposing a first plurality of spools on said pad so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of said pad;   (c) providing a first separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-engaging features being disposed in said predetermined pattern;   (d) disposing said first separator so that said spool-engaging features of said first face each engage a respective one of said spools of said first plurality of spools;   (e) disposing a second plurality of spools on said second face of said first separator so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of the second face of said first separator;   (f) providing a second separator having a first and second face, each face having a plurality of spool-engaging features defined thereupon, said spool-engaging features each being configured so as to engage a spool, said spool-retaining features being disposed in said predetermined pattern;   (g) disposing said second separator so that said spool-engaging features of said first face each engage a respective one of said spools of said second plurality of spools;   (h) disposing a third plurality of spools on said second face of said second separator so that each of said spools is engaged by a respective one of said plurality of spool-engaging features of the second face of said second separator;   (i) optionally, repeating steps (f)-(h) one or more times utilizing at least a third separator and at least a fourth plurality of spools;   (j) providing a cap having a first face having a plurality of spool-engaging features defined upon said first face thereof, said spool-engaging features being disposed in said predetermined pattern; and   (k) disposing said cap so that said spool-engaging features of said first face each engage: a respective one of said spools of said third plurality of spools, or a respective one of said spools of said at least a fourth plurality of spools.