Forks for industrial vehicles and method of making same

1. A fork for a forklift truck comprising:

a toe portion; and

an elongate body portion coupled to the toe portion, the elongate body portion comprising a load portion and a truss portion coupled to the load portion;

wherein the truss portion comprises a first strut coupled to the load portion and extending away from the load portion, a first cross beam coupled to the first strut and extending away from the first strut, a second strut extending away from the first cross beam towards the load portion, a third strut extending away from the load portion, a second cross beam coupled to the third strut and extending away from the third strut, a fourth strut coupled to the second cross beam and extending towards the load portion and coupled to the load portion, and a third cross beam coupled to the second strut and the third strut; and

wherein the load portion and the truss portion of the elongate body portion are formed as a single piece.

2. The fork according to claim 1 , wherein the third cross beam is further coupled to the load portion.

3. The fork according to claim 2 , wherein the third cross beam is coupled to the load portion via integral formation with the load portion.

4. The fork according to claim 1 , where in each of the first, second, third, and fourth struts are coupled to the load portion.

5. The fork according to claim 1 , wherein the load portion comprises a flat surface extending longitudinally away from the toe portion, further comprising:

a stiffener rigidly connected to and extending from the flat surface, wherein the stiffener is sized and located to inhibit longitudinal bending of the body portion.

6. The fork according to claim 1 , wherein the truss portion comprises a first truss and a second truss;

wherein the first truss comprises the first strut coupled to the load portion and extending away from the load portion, the first cross beam coupled to the first strut and extending away from the first strut, the second strut extending away from the first cross beam towards the load portion, the third strut extending away from the load portion, the second cross beam coupled to the third strut and extending away from the third strut, and the fourth strut coupled to the second cross beam and extending towards the load portion and coupled to the load portion, and the third cross beam coupled to the second strut and the third strut; and

wherein the second truss comprises a fifth strut coupled to the load portion and extending away from the load portion, a fourth cross beam coupled to the fifth strut and extending away from the fifth strut, a sixth strut extending away from the fourth cross beam towards the load portion, a seventh strut extending away from the load portion, a fifth cross beam coupled to the seventh strut and extending away from the seventh strut, and an eighth strut coupled to the fifth cross beam and extending towards the load portion and coupled to the load portion, and a sixth cross beam coupled to the sixth strut and the seventh strut.

7. The fork according to claim 6 , wherein the elongate body portion comprises no more than two longitudinal weldments.

8. The fork according to claim 7 , wherein one or more longitudinal weldments are positioned to couple:

(a) the load portion and the first strut;

(b) the load portion and the second strut;

(c) the load portion and the third strut;

(d) the load portion and the fourth strut;

(e) the load portion and the fifth strut;

(f) the load portion and the sixth strut;

(g) the load portion and the seventh strut;

(h) the load portion and the eighth strut; or

(i) a combination thereof.

9. The fork according to claim 6 , wherein the first truss is spaced apart from the second truss to form a central channel sized and shaped to receive a support wheel linkage mechanism.

10. The fork according to claim 6 , wherein:

the third cross beam is coupled to the load portion; and

the sixth cross beam is coupled to the load portion.

11. The fork according to claim 6 , wherein the load portion comprises a flat surface extending longitudinally away from the toe portion, further comprising:

a stiffener rigidly connected to and extending from the flat surface, wherein the stiffener is sized and located to inhibit longitudinal bending of the body portion.

12. The fork according to claim 1 , wherein the load portion comprises a flat surface extending longitudinally away from the toe and a stiffener rigidly connected to the flat surface and parallel to the flat surface; and wherein the stiffener is sized and located to inhibit longitudinal bending of the body.

13. The fork according to claim 12 , wherein the stiffener comprises a flute formed in the flat surface.

14. The fork according to claim 13 , wherein the flute formed in the flat surface extends towards the truss portion.

15. The fork according to claim 13 , wherein the stiffener comprises a plurality of flutes formed in the flat surface.

16. The fork according to claim 1 , wherein the elongate body portion comprises no more than two longitudinal weldments.

17. The fork according to claim 1 , wherein the second and/or third strut is substantially non-perpendicular with the load portion.

18. The fork according to claim 1 , wherein the first strut has a thickness dimension of 5.0 mm or less.

19. The fork according to claim 18 , wherein the first strut has a thickness dimension of 4.5 mm or less.

20. A fork for a forklift truck comprising:

a toe portion; and

an elongate body portion coupled to the toe portion, the elongate body portion comprising a load portion and a truss portion coupled to the load portion;

wherein the truss portion comprises a first strut coupled to the load portion and extending away from the load portion, a first cross beam coupled to the first strut and extending away from the first strut, a second strut extending away from the first cross beam towards the load portion, a third strut extending away from the load portion, a second cross beam coupled to the third strut and extending away from the third strut, a fourth strut coupled to the second cross beam and extending towards the load portion and coupled to the load portion, and a third cross beam coupled to the second strut and the fourth strut; and

wherein the third cross beam is further coupled to the load portion via spot welds.

21. A fork for a forklift truck comprising:

a toe portion; and

an elongate body portion coupled to the toe portion, the elongate body portion comprising a load portion and a truss portion coupled to the load portion;

wherein the truss portion comprises a first strut coupled to the load portion and extending away from the load portion, a first cross beam coupled to the first strut and extending away from the first strut, a second strut extending away from the first cross beam towards the load portion, a third strut extending away from the load portion, a second cross beam coupled to the third strut and extending away from the third strut, a fourth strut coupled to the second cross beam and extending towards the load portion and coupled to the load portion, and a third cross beam coupled to the second strut and the fourth strut;

wherein the elongate body portion comprises no more than two longitudinal weldments; and

wherein one or more longitudinal weldments are positioned to couple:

(a) the load portion and the first strut;

(b) the load portion and the second strut;

(c) the load portion and the third strut;

(d) the load portion and the fourth strut; or

(e) a combination thereof.