Pallet base, intermediate bulk container, method of assembly of an intermediate bulk container, runner and deck structure

Abstract

Transportation of the various parts of Intermediate Bulk Containers requires a lot of storage space and is thus expensive. This problem is overcome by a pallet base (8), in particular a pallet base (8) of an Intermediate Bulk Container (IBC) (1), comprising: —a deck structure (20, 20′, 20″) with a top surface (28) and a bottom surface (29), the top surface defining a load area (27) adapted to support an IBC container (3); —at least one foot structure (21, 21′, 21″) extending from the bottom surface (29); further comprising at least one runner structure (10), the at least one runner structure (10) configured to engage with the at least one foot structure (21, 21′, 21″), preferably using a snap-fit mechanism (13).

1 . A pallet base ( 8 ), in particular a pallet base ( 8 ) of an Intermediate Bulk Container (IBC) ( 1 ), preferably of a caged IBC tote, comprising:
 a deck structure ( 20 ,  20 ′,  20 ″) with a top surface ( 28 ) and a bottom surface ( 29 ), the top surface defining a load area ( 27 ) adapted to support an IBC container ( 3 );   at least one foot structure ( 21 ,  21 ′,  21 ″) extending from the bottom surface ( 29 );   characterized by at least one runner structure ( 1 ), the at least one runner structure ( 10 ) configured to engage with the at least one foot structure ( 21 ,  21 ′,  21 ″), preferably using a snap-fit mechanism ( 13 ).   
     
     
         2 . The pallet base ( 8 ) of  claim 1  characterized in that the at least one foot structure ( 21 ′) is configured as an at least substantially hollow structure such that a second foot structure ( 21 ) of a second pallet base ( 20 ′) stacked on top of the pallet base ( 20 ″) may engage into the at least one foot structure ( 21 ′), wherein the at least one foot structure ( 21 ′) is in particular shaped tapered away from the bottom surface ( 29 ). 
     
     
         3 . The pallet base ( 8 ) of  claim 2 , characterized in that the at least one foot structure ( 21 ′) defines an opening ( 25 ) in the deck structure ( 20 ,  20 ′,  20 ″), such that a second foot structure ( 21 ) of a second pallet base ( 20 ′) may be inserted into the at least one foot structure ( 21 ′). 
     
     
         4 . The pallet base ( 8 ) of  claim 1  characterized in that the at least one foot structure ( 21 ,  21 ′,  21 ″) and the deck structure ( 20 ,  20 ″) are manufactured in an integral construction. 
     
     
         5 . The pallet base ( 8 ) of  claim 1  characterized in that the at least one runner structure ( 10 ) defines at least one engagement region ( 11 ) on a runner top surface ( 15 ), wherein the at least one engagement region ( 11 ) is adapted to at least partially contact the at least one foot structure ( 21 ,  21 ′,  21 ″). 
     
     
         6 . The pallet base ( 8 ) of  claim 5 , characterized in that the at least one runner structure ( 10 ) comprises at least one hook ( 13 ) extending out of a/the runner top surface ( 15 ), in particular in the at least one engagement region ( 11 ), the hook ( 13 ) being adapted to engage with a protrusion on the at least one foot structure ( 21 ,  21 ′,  21 ″), in particular on the inside of the at least one foot structure ( 21 ,  21 ′,  21 ″). 
     
     
         7 . The pallet base ( 8 ) of  claim 5 , characterized in that the at least one engagement region ( 11 ) comprises at least one restraining wall ( 12 ,  12 ′) adapted to prevent a lateral movement of the at least one runner structure ( 10 ) relative to the at least one foot structure ( 21 ,  21 ′,  21 ″). 
     
     
         8 . The pallet base ( 8 ) of  claim 5 , characterized by a de-watering hole ( 14 ) arranged in the engagement region ( 11 ), in particular a through-hole through the at least one runner structure ( 10 ). 
     
     
         9 . The pallet base ( 8 ) of  claim 1  characterized in that the at least one runner structure ( 10 ) has a tapered shape with a top runner surface ( 15 ) and a bottom runner surface ( 16 ), wherein the top runner surface ( 15 ) is narrower than the bottom runner surface ( 16 ). 
     
     
         10 . The pallet base ( 8 ) of  claim 9 , characterized in that the engagement region ( 11 ) is arranged on the top runner surface ( 15 ), the engagement region ( 11 ) extending beyond an edge of the top runner surface ( 15 ) and being configured narrower than a width (W 2 ) of the bottom runner surface ( 16 ). 
     
     
         11 . The pallet base ( 8 ) of  claim 1  characterized by at least one reinforcement structure ( 40 ,  40 ′), arranged on, in, or below the deck structure ( 20 ,  20 ′,  20 ″), preferably extending at least along 60% of a width of the deck structure ( 20 ,  20 ′,  20 ″). 
     
     
         12 . The pallet base ( 8 ) of  claim 11 , characterized in that the deck structure ( 20 ,  20 ′,  20 ″) has at least one, preferably two, reinforcement recess ( 41 ,  41 ′) formed inside the deck structure ( 28 ) of the deck structure ( 20 ,  20 ′,  20 ″) adapted to take a/the reinforcement structure ( 40 ,  40 ′). 
     
     
         13 . The pallet base ( 8 ) of  claim 1  characterized in that the deck structure ( 20 ,  20 ′,  20 ″) comprises a plurality of ribs forming a grid along the top surface ( 28 ) and bottom surface ( 29 ), wherein the grid comprises a plurality of through holes from the top surface ( 28 ) to the bottom surface ( 29 ). 
     
     
         14 . The pallet base ( 8 ) of  claim 1  characterized in that the deck structure ( 20 ,  20 ′,  20 ″) has a plurality of cage connection regions adapted to be attached to a cage, in particular a plurality of threads ( 23 ) for screws, arranged on an outer edge of the deck structure ( 20 ,  20 ′,  20 ″). 
     
     
         15 . The pallet base ( 8 ) of  claim 1  characterized in that the at least one runner structure ( 10 ) runs substantially straight in parallel to the bottom surface ( 29 ) of the deck structure ( 20 ,  20 ′,  20 ″) when engaged with the at least one foot structure ( 21 ,  21 ′,  21 ″). 
     
     
         16 . The pallet base ( 8 ) of  claim 1  characterized in that a plurality of foot structures ( 21 ,  21 ′,  21 ″) together with respective runner structures ( 10 ) form at least three runner rows on the bottom surface ( 29 ) of the deck structure ( 20 ,  20 ′,  20 ″), wherein the rows are distanced such that a fork, for example of a forklift or a low lift pallet truck, is insertable between the rows and lift the pallet base ( 8 ). 
     
     
         17 . An Intermediate Bulk Container ( 1 ), in particular a caged IBC container, comprising:
 a pallet base ( 8 ) as defined in any of the preceding claims;   a cage ( 2 );   a container ( 3 );   wherein the container ( 3 ) is arranged within the cage ( 2 ) and the cage ( 2 ) is joined with the pallet base ( 8 ).   
     
     
         18 . A method of assembly ( 30 ) of an Intermediate Bulk Container ( 1 ), the method comprising the following steps:
 Attaching ( 31 ) at least one runner structure ( 10 ) of a pallet base ( 8 ) to a deck structure ( 20 ,  20 ′,  20 ″), in particular a runner structure ( 10 ) and/or a deck structure ( 20 ,  20 ′,  20 ″) of a pallet base ( 8 ) of any of the  claims 1  to  16 ;   Arranging a cage ( 2 ) on the deck structure ( 20 ,  20 ′,  20 ″);   Joining ( 33 ) the cage ( 2 ) with the deck structure ( 20 ,  20 ′,  20 ″);   Placing ( 34 ) a container ( 3 ) on a load surface ( 27 ) of the deck structure ( 20 ,  20 ″) inside the container ( 3 ).   
     
     
         19 . A runner structure ( 10 ) of the pallet base ( 8 ) according to  claim 1 . 
     
     
         20 . A deck structure ( 20 ,  20 ′,  20 ″) of the pallet base ( 8 ) according to  claim 1 .