This disclosure pertains to a pallet that is constructed entirely of plastic material. In particular, this disclosure pertains to a pallet constructed as one, unitary piece of plastic material, for example recycled plastic material. The pallet being constructed entirely of plastic material is also recyclable.
The elimination of wood in the construction of the pallet makes the pallet lighter, reduces the cost of manufacturing the pallet, and reduces the amount of wasted or discarded wood. The one piece plastic pallets, constructed in the manner of the pallet to be described are nestable, enabling shipping of a large number of nested pallets in a reduced space than that required when shipping a large number of wood pallets. The reduced weight of the plastic pallet also saves transportation costs by reducing fuel consumption.
The wood pallet is by far the most commonly used pallet in the United States.
A plurality of top deck boards 16 are attached to the top surfaces of the stringers 12 and extend across the stringers. The top deck boards 16 are also constructed of wood. In the pallet 10 represented in
The pallet 10 is also constructed with a plurality of bottom deck boards 18. The bottom deck boards 18 are also constructed of wood. As represented in
The wood used in the construction of the pallet 10 makes the pallet heavy, expensive, bulky and wood intensive, The wood is also susceptible to mold and mildew. Widespread use of wood in pallets has resulted in environmental problems and waste disposal problems.
The all-in-one plastic pallet of this disclosure eliminates the wood needed to construct a pallet and thereby lowers the cost of constructing a new pallet and lowers the weight of the pallet. The configuration of the pallet to be described is nestable, which allows almost twice as many all-in-one plastic pallets to ship from a manufacturer to the end user than wood pallets. The pallet is constructed entirely of plastic. The pallet could be constructed of recycled plastic material, and is itself recyclable which further lowers the cost of the pallet. The all-in-one plastic pallet of this disclosure entirely eliminates wood from the construction of the pallet.
The pallet has a top perimeter surface on a top of the pallet. The top perimeter surface has a rectangular configuration and is a continuous surface that extends completely around a perimeter of the top of the pallet. The top perimeter surface is a flat surface positioned in a single plane and is an outermost surface on the top of the pallet.
A perimeter channel is recessed into the top of the pallet and extends from the top perimeter surface into an interior of the pallet. The perimeter channel has a rectangular configuration that extends completely around the top of the pallet. The perimeter channel is positioned adjacent the top perimeter surface and inside of the top perimeter surface.
There is a first platform surface on the top of the pallet. The first platform surface has a rectangular configuration and is a flat surface positioned in the single plane of the top perimeter surface. The first platform surface is adjacent the perimeter channel and positioned inside the perimeter channel with the perimeter channel extending completely around the first platform surface.
There is a second platform surface on the top of the pallet. The second platform surface has a rectangular configuration and is a flat surface positioned in the single plane of the top perimeter surface and the first platform surface. The second platform surface is positioned adjacent the first platform surface with the perimeter channel extending completely around the first platform surface and the second platform surface.
There is a center ridge surface on the top of the pallet. The center ridge surface has an elongate, rectangular configuration and extends across the top of the pallet between the first platform surface and the second platform surface. The center ridge surface is a flat surface positioned in the single plane of the top perimeter surface, the first platform surface and the second platform surface.
The pallet has a bottom perimeter surface on a bottom of the pallet. The bottom perimeter surface has a rectangular configuration and is a continuous surface that extends completely around a perimeter of the bottom of the pallet. The bottom perimeter surface is a flat surface positioned in a single plane and is an outermost surface on the bottom of the pallet. The bottom perimeter surface and the top perimeter surface are parallel and they are separated by a vertical height dimension of the pallet. The vertical height dimension between the top perimeter surface and the bottom perimeter surface is larger than a height dimension of a blade of a forklift.
To enable nesting the pallet on to a second pallet having a like construction, the bottom perimeter surface is configured and dimensioned to be received in and fit into a perimeter channel recessed into a top of the second pallet in response to the pallet being stacked on top of the second pallet and nested into the perimeter channel recessed into the top of the second pallet.
There is a first chamber in the bottom of the pallet. The first chamber is an empty, hollow void that extends from the bottom perimeter surface into the interior of the pallet to a first chamber surface that is opposite the first platform surface on the top of the pallet. The first chamber is adjacent the bottom perimeter surface and positioned inside the bottom perimeter surface with the bottom perimeter surface extending completely around the first chamber. To enable nesting the pallet on the second pallet having a like construction, the first chamber has a rectangular configuration that is dimensioned to receive in the first chamber a first platform surface of the second pallet in response to the pallet being stacked on and nested into the second pallet.
There is a second chamber in the bottom of the pallet. The second chamber is an empty, hollow void that extends from the bottom perimeter surface into the interior of the pallet to a second chamber surface that is opposite the second platform surface on the top of the pallet. The second chamber is adjacent the bottom perimeter surface and positioned adjacent the first chamber inside the bottom perimeter surface with the bottom perimeter surface extending completely around the second chamber. To enable nesting the pallet on to the second pallet having a like construction, the second chamber has a rectangular configuration that is dimensioned to receive in the second chamber a second platform surface of the second pallet in response to the pallet being stacked on and nested into the second pallet.
There is a third chamber in the bottom of the pallet. The third chamber is an empty, hollow void that extends from the bottom perimeter surface into the interior of the pallet to a third chamber surface that is opposite the center ridge surface on the top of the pallet. The third chamber is adjacent the bottom perimeter surface and positioned inside the bottom perimeter surface between the first chamber and the second chamber with the bottom perimeter surface extending completely around the first chamber, the second chamber and the third chamber. To enable nesting the pallet on to the second pallet having a like construction, the third chamber has an elongate rectangular configuration that is dimensioned to receive in the third chamber a center ridge surface of the second pallet in response to the pallet being stacked on and nested into the second pallet.
The top perimeter surface on the top of the pallet, the bottom perimeter surface on the bottom of the pallet, the perimeter channel into the top of the pallet, the first platform surface on the top of the pallet, the second platform surface on the top of the pallet, the center ridge surface on the top of the pallet, the first chamber in the bottom of the pallet, the second chamber in the bottom of the pallet and the third chamber in the bottom of the pallet are all integrally formed as a single piece or as a single unit of plastic material. The all-in-one plastic pallet constructed entirely of plastic is lightweight and is less expensive to manufacture than a typical wood pallet. The particular configuration and construction of the all-in-one plastic pallet makes the pallet nestable with other pallets of like construction, rackable for storage of the all-in-one plastic pallet in a conventional pallet storage rack, and stackable on top of products supported on a pallet of like construction without causing damage to the products.
Further features of the all-in-one plastic pallet are set forth in the following detailed description and in the drawing figures.
As represented in
A perimeter channel 24 is recessed into the top of the pallet 20. The perimeter channel 24 extends from the top perimeter surface 22 into an interior of the pallet 20. Four, vertically oriented outer side walls 26 extend downwardly from the top perimeter surface 22 and surround the perimeter channel 24. The outer side walls 26 define the vertical height dimension of the pallet 20. Changing the vertical height dimension of the side walls 26 changes the vertical height dimension of the pallet 20. A pair of slots 28 are provided through each of the four outer side walls 26. The slots 28 are dimensioned to receive the blades of a forklift through the slots when lifting the pallet 20 with the forklift. The perimeter channel 24 has a rectangular configuration that extends completely around the top of the pallet 20. More specifically, the perimeter channel 24 has a square configuration. The perimeter channel 24 is positioned adjacent the top perimeter surface 22 and just inside of the top perimeter surface 22. No part of the top perimeter surface 22 extends across the top opening of the perimeter channel 29.
There is a first platform surface 32 on the top of the pallet 20. The first platform surface 32 is formed from a plurality of slats 34 that are integrally connected together to form the first platform surface 32. The plurality of slats 34 give the first platform surface 32 a rectangular configuration. The plurality of slats 34 are all positioned in a single plane and define a flat surface of the first platform surface 32. Four inner side walls 36 extend downwardly from the slats 34 and extend around the slats 34 of the first platform surface 32. The four inner side walls 36 integrally connect the slats 34. The four inner side walls 36 position the first platform surface 32 defined by the slats 34 in the single plane of the top perimeter surface 22. There are slots 38 through the inner side walls 36 that align with slots 28 through the outer side walls 26. The slots 38 through the inner side walls 36 are also dimensioned to receive the forks of a forklift through the slots. The four inner side walls 36 position the first platform surface 32 adjacent the perimeter channel 24 on an opposite side of the perimeter channel 24 from the top perimeter surface 22. The first platform surface 32 is positioned just inside of the perimeter channel 24 and the perimeter channel 24 extends completely around the first platform surface 32.
There is a second platform surface 42 on the top of the pallet 20. The second platform surface 42 has substantially the same construction as the first platform surface 32. The second platform surface 42 is formed from a plurality of slats 44 that are integrally connected together to form the second platform surface 42. The plurality of slats 44 give the second platform surface 42 a rectangular configuration. The plurality of slats 44 are all positioned in a single plane and define a flat surface of the second platform surface 42. Four inner side walls 46 extend downwardly from the slats 44 and extend around the slats 44 of the second platform surface 42. The four inner side walls 46 integrally connect the slats 44. The four inner side walls 46 position the second platform surface 42 defined by the slats 44 in the single plane of the top perimeter surface 22. There are slots 48 through the inner side walls 46 that align with slots 28 through the outer side walls 26. The slots 48 through the inner side walls 46 are also dimensioned to receive the forks of a forklift through the slots. The four inner side walls 46 position the second platform surface 42 adjacent the perimeter channel 24 on an opposite side of the perimeter channel 24 from the top perimeter surface 22. The second platform surface 42 is positioned just inside of the perimeter channel 24 and the perimeter channel 24 extends completely around the second platform surface 42. The second platform surface 42 is positioned adjacent the first platform surface 32 with the perimeter channel 24 extending completely around the first platform surface 32 and the second platform surface 42.
There is a center ridge surface 52 on the top of the pallet 20. The center ridge surface 52 is a solid surface with an elongate, rectangular configuration that extends across the top of the pallet from one side of the perimeter channel 24 to the opposite side of the perimeter channel 24. The center ridge surface 52 is positioned between the first platform surface 32 and the second platform surface 42. The center ridge surface 52 is a flat surface positioned in the single plane of the top perimeter surface 22, the first platform surface 32 and the second platform surface 42. Four center side walls 54 extend downwardly from the center ridge surface 52 and position the center ridge surface 52 in the single plane of the top perimeter surface 22, the first platform surface 32 and the second platform surface 42. There are slots 56 through the center side walls 54 adjacent the first platform surface 32 and the second platform surface 42. The slots 56 are dimensioned to receive blades of a forklift through the slots 56.
A first central channel 62 is recessed into the top of the pallet 20 and extends downwardly from the first platform surface 32 and from the center ridge surface 52 into the interior of the pallet 20. The first central channel 62 extends across the top of the pallet 20 with opposite ends of the first center channel 62 intersecting the perimeter channel 24 at opposite ends of the pallet 20. The first central channel 62 separates the first platform surface 32 from the central ridge surface 52.
A second central channel 64 is recessed into the top of the pallet 20 and extends downwardly from the second platform surface 42 and from the center ridge surface 52 into the interior of the pallet 20. The second central channel 64 extends across the top of the pallet 20 with opposite ends of the second center channel 64 intersecting the perimeter channel 24 at opposite ends of the pallet 20. The second central channel 64 separates the second platform surface 42 from the central ridge surface 52.
As represented in
As represented in
There is a first chamber 68 in the bottom of the pallet 20. The first chamber 68 is an empty, hollow void that extends upwardly from the bottom perimeter surface 66 into the interior of the pallet 20 to a first chamber surface 72. The first chamber surface 72 is opposite the first platform surface 32 on the top of the pallet 20. The first chamber 68 is inside the four inner side walls 36 of the first platform surface 32. The bottom perimeter surface 66 extends completely around the first chamber 68. As represented in
There is a second chamber 74 in the bottom of the pallet 20. The second chamber 74 is an empty, hollow void that extends upwardly from the bottom perimeter surface 66 into the interior of the pallet 20 to a second chamber surface 76. The second chamber surface 76 is opposite the second platform surface 42 on the top of the pallet 20. The second chamber 74 is inside the four inner side walls 46 of the second platform surface 42. The bottom perimeter surface 66 extends completely around the second chamber 74. As represented in
There is a third chamber 82 in the bottom of the pallet 20. The third chamber 82 is an empty, hollow void that extends upwardly from the bottom perimeter surface 66 into the interior of the pallet 20 to a third chamber surface 84. The third chamber surface 84 is opposite the center ridge surface 52 on the top of the pallet 20. The third chamber 82 is inside the center side walls 54 of the center ridge surface 52. The bottom perimeter surface 66 extends completely around the third chamber 82. As represented in
A first central surface 86 extends across the bottom of the pallet 20. Opposite ends of the first central surface 86 intersect the bottom perimeter surface 66 on opposite sides of the pallet 20. The first central surface 86 is a solid surface with an elongate, rectangular configuration that extends across the bottom of the pallet from one side of the bottom perimeter surface 66 to the opposite side of the bottom perimeter surface 66. The first central surface 86 is a flat surface positioned in the single plane of the bottom perimeter surface 66. The first central surface 86 is positioned between the first chamber 68 and the third chamber 82. The first central surface 86 is formed integrally with a bottom edge of one of the inner side walls 36 of the first platform surface 32 and with the bottom edge of one of the center side walls 54 of the center ridge surface 52.
A second central surface 88 extends across the bottom of the pallet 20. Opposite ends of the second central surface 88 intersect the bottom perimeter surface 66 on opposite sides of the pallet 20. The second central surface 88 is a solid surface with an elongate, rectangular configuration that extends across the bottom of the pallet from one side of the bottom perimeter surface 66 to the opposite side of the bottom perimeter surface 66. The second central surface 88 is a flat surface positioned in the single plane of the bottom perimeter surface 66. The second central surface 88 is positioned between the second chamber 74 and the third chamber 82. The second central surface 88 is formed integrally with a bottom edge of one of the inner side walls 46 of the second platform surface 42 and with the bottom edge of one of the center side walls 54 of the center ridge surface 52.
The top perimeter surface 22 on the top of the pallet 20, the bottom perimeter surface 66 on the bottom of the pallet 20, the perimeter channel 24 in the top of the pallet 20, the first platform surface 32 on the top of the pallet 20, the second platform surface 42 on the top of the pallet 20, the center ridge surface 52 on the top of the pallet 20, the first chamber 68 in the bottom of the pallet 20, the second chamber 74 in the bottom of the pallet 20, the third chamber 82 in the bottom of the pallet 20, the first central surface 86 on the bottom of the pallet 20 and the second central surface 88 on the bottom of the pallet 20 are all integrally formed as a single piece or as a single unit of plastic material. The pallet 20 could be formed by injection molding, by compression molding, or by another equivalent method. Together the top perimeter surface 22, the first platform surface 32, the second platform surface 42 and the central ridge surface 52 form a planar support surface having a surface area that supports products arranged in a three dimensional arrangement on the top of the pallet 20, for example a three-dimensional arrangement of boxes, bulk bags, etc. Together the bottom perimeter surface 66, the first central surface 86 and the second central surface 88 on the bottom of the pallet 20 together form a planar surface that can be positioned on and engage on a three-dimensional arrangement of products supported on a second pallet of like construction without causing damage to the products. The all-in-one plastic pallet constructed entirely of plastic material as a single piece of plastic material is lightweight and is less expensive to manufacture than a typical wood pallet. The particular configuration and construction of the all-in-one plastic pallet 20 makes the pallet nestable with other pallets of like construction, rackable for storage of the all-in-one plastic pallet 20 in a conventional pallet storage rack, and makes the pallet 20 recyclable.
As various modifications could be made in the construction of the all-in-one plastic pallet and its method of operation herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.
This application claims the benefit of the filing date of provisional patent application Ser. No. 62/823,078, which was filed on Mar. 25, 2019. Provisional patent application Serial No. 62/823,078 is herein incorporated by reference.
Number | Date | Country | |
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62823078 | Mar 2019 | US |