Pallet truck with pressed fork structure

1. A pallet truck comprising:

a lift assembly;

a fork assembly having a fork structure extending generally laterally from the lift assembly, the fork structure including:

an elongate body portion having:

a top wall;

opposing sidewalls integrally formed with the top wall; and

bottom walls integrally formed with and extending inwardly from respective ones of the opposing sidewalls; and

an outboard end portion integrally formed with the body portion and projecting therefrom, the outboard end portion including a tip sidewall defining a tip region for guiding entry of the fork assembly beneath a pallet; and

a linkage system having a push bar operably coupled to a load roller assembly at the outboard end portion of the fork structure, the load roller assembly having a wheel fork that is pivotably coupled to the outboard end portion via a pivot feature that is received within an opening of the tip sidewalk;

wherein the top wall, the opposing sidewalls, and the bottom walls of the body portion form an interior channel having a “C”-shaped cross section configured to receive the push bar.

2. The pallet truck of claim 1 , wherein the fork structure includes a first region, a second region, and a seam between the first and second regions, wherein the first region is mechanically bent or pressed adjacent the seam to form the opposing sidewalls of the body portion, and wherein the second region is mechanically pressed adjacent the seam to form the tip sidewall of the outboard end portion.

3. The pallet truck of claim 1 , wherein a portion of the top wall of the fork structure extends outboard of the opposing sidewalls of the body portion and terminates into the tip sidewall.

4. The pallet truck of claim 3 , wherein the tip sidewall extends generally downwardly from the portion of the top wall and defines a cavity therewith.

5. The pallet truck of claim 4 , wherein:

each of the opposing sidewalls of the body portion terminates at a vertical edge that is inset from the tip sidewall; and

the load roller assembly includes an axle support member that is received into the cavity and configured to engage the vertical edge of a corresponding one of the opposing sidewalls.

6. The pallet truck of claim 4 , wherein:

the fork assembly further includes a guide member that is received into the cavity; and

the guide member has a convex surface configured to reduce resistance between the outboard end portion of the fork structure and objects on a floor surface over which the load roller assembly is lifted during use.

7. A method for manufacturing a fork structure for use with a pallet truck, the method comprising:

cutting a sheet of material to form a first region, a second region, and a seam between the first and second regions;

bending or pressing the first region to form a body portion of the fork structure, the body portion having:

a top wall;

opposing sidewalls that are integral with the top wall; and

bottom walls that are integral with and extend from respective ones of the opposing sidewalls; and

pressing the second region, including a portion of the top wall that extends beyond the body portion, to form a tip region that is integral with the body portion.

8. The method of claim 7 , wherein pressing the second region includes forming a cavity in the tip region, and wherein the method further comprises inserting a guide member into the cavity and attaching the guide member to the tip region.

9. The method of claim 7 , wherein pressing the second region includes forming a cavity in the tip region, and wherein the method further comprises:

defining a vertical edge at one of the opposing sidewalls that is inset from a sidewall of the tip region; and

inserting an axle support member into the cavity, wherein the axle support member engages the vertical edge.

10. The method of claim 7 , wherein the sheet of material comprises steel.

11. The method of claim 10 , wherein the sheet of material has a thickness of about ¼ inch.

12. A pallet truck comprising:

a lift assembly;

a fork assembly having a fork structure extending generally laterally from the lift assembly, the fork structure including:

an elongate body portion having:

a top wall; and

opposing sidewalls integrally formed with the top wall;

wherein a portion of the top wall extends outboard of the opposing sidewalls;

an outboard end portion integrally formed with the body portion and projecting therefrom, the outboard end portion including:

a tip sidewall defining a tip region for guiding entry of the fork assembly beneath a pallet;

wherein the portion of the top wall terminates into the tip sidewall; and

wherein the tip sidewall extends generally downwardly from the portion of the top wall and defines a cavity therewith;

a load roller assembly at the outboard end portion of the fork structure, the load roller assembly having a wheel fork that is pivotably coupled to the outboard end portion via a pivot feature that is received within an opening of the tip sidewall; and

a guide member received into the cavity, the guide member having a convex surface configured to reduce resistance between the outboard end portion of the fork structure and objects on a floor surface over which the load roller assembly is lifted during use.

13. The pallet truck of claim 12 , wherein the body portion of the fork structure includes bottom walls integrally formed with and extending inwardly from respective ones of the opposing side walls.

14. The pallet truck of claim 12 , wherein the fork structure includes a first region, a second region, and a seam between the first and second regions, wherein the first region is mechanically bent or pressed adjacent the seam to form the opposing sidewalls of the body portion, and wherein the second region is mechanically pressed adjacent the seam to form the tip sidewall of the outboard end portion.

15. The pallet truck of claim 12 , wherein each of the opposing sidewalls of the body portion terminates at a vertical edge that is inset from the tip sidewall.

16. The pallet truck of claim 15 , the load roller assembly includes an axle support member that is received into the cavity and configured to engage the vertical edge of a corresponding one of the opposing sidewalls.