TWIN SHEET PLASTIC PALLET

Abstract: A twin sheet pallet including an upper sheet (12) thermoformed to define a planar main body portion (12a) and a plurality of legs (12b) extending downwardly from the main body portion, and a lower sheet (14) thermoformed to define a planar main body portion (14a) and a plurality of legs (14b) extending downwardly from the lower sheet main body portion. The upper sheet is positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet mainbody portion to define a twin sheet platform structure. The lower sheet further includes a tower structure (14g) extending upwardly from the lower sheet main body portion in surrounding relation to each upper sheet leg. Each tower structure comprises a plurality of circumferentially spaced vertical pins (14h), each pin including a top wall (14j).

Description: TWIN SHEET PLASTIC PALLET Background of the Invention This invention relates to pallets and more particularly to a pallet formed of twin sheets of plastic material. Pallets have traditionally been formed of wood. Wood pallets, however, have many disadvantages. For example, they are subject to breakage and thus are not usable for an extended period of time. They are also difficult to maintain in a sanitary condition, thus limiting their useability in applications where sanitation is important such, for example, as in food handling applications. In an effort to solve some of the problems associated with wood pallets, plastic pallets have been employed with some degree of success. For example, in one generally successful form of plastic pallet design, a twin sheet construction has been used in which upper and lower plastic sheets are formed in separate molding operations and the two sheets are then selectively fused or knitted together in a suitable press to form a reinforced double wall structure. Although such plastic pallets have been durable, have been reusable over an extended period of time, and have been easy to maintain in a sanitary condition, they suffer from the disadvantage of costing considerably more than comparable wooden pallets, thereby limiting their commercial acceptance. Although manufacturing costs are reflected to some extent in the cost of the plastic pallets, the main reason that the plastic pallets cost considerably more than the comparable wooden pallets is that they require a given amount of relatively expensive plastic material for a given measure of pallet strength and the required plastic material has a given cost that constitutes a substantial portion of the total cost of the pallet-. Summary of the Invention This invention is directed to the provision of an improved plastic pallet. More specifically, this invention is directed to the provision of a plastic pallet having improved strength characteristics for a given amount of plastic material employed to form the pallet. The plastic pallet of the invention is of the type including an upper sheet and a lower sheet. The upper sheet is thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the main body portion at spaced locations with each leg opening in the main body portion and including an annular downwardly extending side wall and a bottom wall. The lower sheet is thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the lower sheet main body portion at spaced locations with each lower sheet leg opening in the lower sheet main body portion and including an annular downwardly extending side wall and a bottom wall. The upper sheet is positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet main body portion to define a twin sheet platform structure for the pallet. According to the invention, the lower sheet further includes a tower structure extending upwardly from the lower sheet main body portion in surrounding relation to the side wall of each upper sheet leg with each tower structure including a top wall structure positioned against and fused to the under face of the upper sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg. This lower sheet tower structure, positioned and fused in surrounding relation to each upper sheet leg, provides an extremely strong pallet for a given amount of plastic material and specifically provides a pallet having excellent leg strength, both in compression and in shear. According to a further feature of the invention, each tower structure comprises a plurality of spaced vertical pins upstanding from the lower sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg and each including a top wall fused to the under face of the upper sheet main body portion. This spaced pin construction provides a convenient and effective means of girdling the upper region of each upper sheet leg to preclude unwanted distortion of the pallet leg structures. According to a further feature of the invention, each pin further includes an annular side wall and the annular side wall of each pin is fused to the annular side wall of the respective upper sheet leg. The fusing of the annular side walls of the pins to the annular side walls of the respective upper sheets legs further strengthens the legs of the pallet. According to a further feature of the invention, the annular side wall of each upper sheet leg defines a plurality of circumferentially spaced vertical columns extending downwardly from the upper sheet main body portion, and each column is positioned between and fused to successive vertical pins of the respective lower sheet tower structure. This intermeshing relation of lower sheet pins and upper sheet columns provides a solid girdle structure fixedly surrounding each upper sheet leg structure to further strengthen the pallet legs. According to a further feature of the invention, the annular side wall of each upper sheet leg further defines a vertical rib extending downwardly from each column and fused to the side wall of the respective lower sheet leg. This vertical rib structure extends the double wall twin sheet construction downwardly and into the lower regions of the leg. According to a further feature of the invention, the lower sheet further includes a vertical rib extending downwardly from each pin and fused to the annular side wall of the respective upper sheet leg between successive upper sheet ribs. .The intermeshing relation of the upper sheet ribs and the lower sheet ribs provides a strong, double wall construction for the entirety of each leg. Brief Description of the Drawings FIGURE 1 is a perspective view of a plastic pallet employing a twin sheet construction; FIGURE 2 is. a cross-sectional view taken on line 2-2 of Figure 1; FIGURES 3 and 4 are cross-sectional views taken on lines 3-3 and 4-4 of Figure 2; FIGURE 5 is a cross-sectional view of a lower sheet of the pallet; FIGURE 6 is an exploded view showing the interrelationship of the leg structures of the upper and lower sheets of the pallet; FIGURE 7 is a bottom view of a leg of the pallet; and FIGURE 8 is a detail view showing the intermeshing, fused together relationship of the leg structures of the upper and lower sheets. Detailed Description of the Preferred Embodiment The pallet 10 of the invention (Figures 1 and 2) is preferably formed in a vacuum forming process and includes an upper polyethylene skin or sheet 12 and a lower polyethylene skin or sheet 14 fused or knitted to the upper sheet at various points to provide the desired pallet configuration and desired pallet strength. Upper sheet 12 has a rectangular configuration and includes a planar main body portion 12a, and a plurality of legs 12b extending downwardly from the main body portion at circumferentially spaced locations around the periphery of the main body portion. Each leg 12b opens in main body portion 12a and includes an annular downwardly extending side wall 12c and a bottom wall 12d. A central leg 12b is also provided to provide, for example, a nine- legged pallet construction. Lower sheet 14 has a rectangular configuration matching the rectangular configuration of upper sheet 12 and includes a main body portion 14a and a plurality of legs 14b extending downwardly from the lower sheet main body portion at circumferentially spaced locations around the periphery of the lower sheet main body portion. Each lower sheet leg 14b opens in lower sheet main body portion 14a and includes an annular downwardly extending side wall 14c and a bottom wall 14d. A central leg 14b is also provided to match the central leg of the upper sheet . Upper sheet 12 is positioned in overlying relation to lower sheet 14 with each upper sheet leg 12b nestingly received in and fused to a respective lower sheet leg 14b. Upper sheet main body portion 12a is spaced above lower sheet main body portion 14a, as for example by the use of fused together bosses 12e and 14e, to define a twin sheet platform structure 16 for the pallet. Platform structure 16 is bounded and defined by an outer circumferential seam 18 formed by fused together peripheral portions 12f and 14f of the upper and lower sheets. According to the invention, lower sheet 14 further includes a tower structure 14g (Figures 6 and 8) extending upwardly from the lower sheet main body portion 14a in surrounding relation to the side wall 12c of each upper sheet leg 12b. Each tower structure 14g comprises a plurality of circumferentially spaced vertical pins 14h upstanding from lower sheet main body portion 14a in surrounding relation to the side wall of the respective upper sheet leg 12b. Each pin 14h is hollow, has an annular side wall 14i of conical upwardly inwardly tapering configuration, and further includes a top wall 14j . The inboard arcuate portions of pins 14h extend inboard with respect to annular side wall 14c and extend downwardly from main body portion 14a to form vertical ribs 14k extending downwardly from each pin 14h within annular side wall 14c. Each rib 14k extends from lower sheet main body portion 14a to the bottom wall 14d of the respective leg. Because of the deep draw characteristics of the vacuum molding operation required to form the pins 14h, a web 141 of doubled-over configuration is formed between each adjacent pair of legs 14i during the vacuum forming process to form a seam line 141 in the under face of main body portion 14a extending between the adjacent pins. In further accordance with the invention, the upper region of the annular side wall 12c of each upper sheet leg 12b defines a plurality of circumferentially spaced vertical columns 12g extending downwardly from upper sheet main body portion 12a by a distance corresponding generally to the height of pins 14h. Columns 12g are hollow, open radially inwardly with respect to the central opening defined by annular side wall 12c, terminate in a bottom wall 12h, and are circumferentially staggered with respect to pins 14h so as to intermesh with the pins in the assembled configuration of the upper and lower sheets . The annular side wall 12c of each upper sheet leg further defines a plurality of circumferentially spaced vertical ribs 12i extending downwardly from each column 12g so as to form a downward extension of the column and so as to protrude radially outwardly from the annular side wall 12c of the upper sheet leg portion. Each vertical rib 12i extends from the bottom wall 12h of the respective column to the bottom wall 12d of the respective leg 12b. In the fused together, knitted configuration of the upper and lower sheets to form the pallet, and as best seen in Figure 8, pins 14h are intermeshed or interspersed with respect to columns 12g; columns 12g abut against and are fused to webs 141; columns 12g abut against and are fused to the annular side walls 14i of adjacent pins; pins 14h abut against and are fused to the annular side walls 12c of the upper sheet legs; the bottom walls 12k of the columns are fused to upper sheet main body portion 14a inboard of webs 141; and pin top walls 14j are fused to the under face of upper sheet main body portion 12a. The intermeshed, fused together columns and pins coact to define a rigid girdle or stockade structure at the upper region of each pallet leg which rigidly surrounds the pallet leg and acts to preclude distortion of the leg under even extreme compressive or shear forces . Further, and as best seen in Figure 4, ribs 14k are intermeshed with ribs 12i to form a rigid twin sheet construction for the lower region of each leg. Specifically, each rib 14k is fused to a respective portion of the annular side wall portion 12c of the upper sheet and each rib 12i is fused to a respective portion of the annular side wall portion 14c of the lower sheet to form a double wall construction extending around the entire circumference of the lower region of each leg. The twin sheet pallet construction of the invention will be seen to provide an extremely strong pallet for a given amount of plastic material and, specifically, will be seen to provide a pallet having extremely good strength characteristics in the vulnerable area of the pallet legs . Whereas a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention.

Claims: Claims What is claimed is : 1. A twin sheet pallet including an upper sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the main body portion at spaced locations with each leg opening in the main body portion and including an annular downwardly extending side wall and a bottom wall, and a lower sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the lower sheet main body portion at spaced locations with each lower sheet leg opening in the lower sheet main body portion and including an annular downwardly extending side wall and a bottom wall, the upper sheet being positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet main body portion to define a twin sheet platform structure for the pallet, characterized in that: the lower sheet further includes a tower structure extending upwardly from the lower sheet main body portion in surrounding relation to the side wall of each upper sheet leg with each tower structure including a top wall structure positioned against and fused to the under face of the upper sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg. 2. A pallet according to claim 1 wherein each tower structure comprises a plurality of spaced vertical pins upstanding from the lower sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg and each including a top wall fused to the under face of the upper sheet main body portion. 3. A pallet according to claim 2 wherein each pin further includes an annular side wall and the annular side wall of each pin is fused to the annular side wall of the respective upper sheet leg. 4. A pallet according to claim 3 wherein each tower structure further includes upstanding web structures interconnecting the annular side walls of at least certain of adjacent pins. 5. A pallet according to claim 2 wherein each pin is hollow and opens downwardly. 6. A pallet according to claim 2 wherein the annular side wall of each upper sheet leg defines a plurality of circumferentially spaced vertical columns extending downwardly from the upper sheet main body portion and each positioned between and fused to two successive vertical pins of the respective lower sheet tower structure . 7. A pallet according to claim 6 wherein the annular side wall of each upper sheet leg further defines a vertical rib extending downwardly from each column and fused to the side wall of the respective lower sheet leg. 8. A plastic pallet according to claim 7 wherein the lower sheet further includes a vertical rib extending downwardly from each pin and fused to the annular side wall of the respective upper sheet leg between successive upper sheet ribs . 9. A twin sheet pallet comprising: an upper sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the main body portion at circumferentially spaced locations around the periphery of the main body portion with each leg opening in the main body portion and including an annular downwardly extending side wall and a bottom wall; and a lower sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the lower sheet main body portion at circumferentially spaced locations around the periphery of the lower sheet main body portion with each lower sheet leg opening in the lower sheet main body portion and including an annular downwardly extending side wall and a bottom wall; the upper sheet being positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet main body portion to define a twin sheet platform structure for the pallet; the lower sheet further including a tower structure extending upwardly from the lower sheet main body portion in surrounding relation to the side wall of each upper sheet leg with each tower structure including a top wall structure positioned against and fused to the under face of the upper sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg; each tower structure comprising a plurality of spaced vertical pins upstanding from the lower sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg and each including a top wall fused to the under face of the upper sheet main body portion; and the top walls of the vertical pins of each tower structure constituting the top wall structure of the tower structure . 10. A pallet according to claim 9 wherein each pin further includes an annular side wall and the annular side wall of each pin is fused to the annular side wall of the respective upper sheet leg. 11. A pallet according to claim 10 wherein each tower structure further includes upstanding web structures interconnecting the annular side walls of at least certain of adjacent pins. 5 12. A pallet according to claim 9 wherein each pin is hollow and opens downwardly. 13. A pallet according to claim 9 wherein the annular side wall of each upper sheet leg defines a plurality of circumferentially spaced vertical columns 10 extending downwardly from the upper sheet main body portion and each positioned between and fused to two successive vertical pins of the respective lower sheet tower structure. 14. A pallet according to claim 13 wherein the 15 annular side wall of each upper sheet leg further defines a vertical rib extending downwardly from each column and fused to the side wall of the respective lower sheet leg. 15. A pallet according to claim 14 wherein the lower sheet further includes a vertical rib extending • 20 downwardly from each pin and fixed to the annular side wall of the respective upper sheet leg between successive upper sheet ribs . 16. A twin sheet pallet including: an upper sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the main body portion at circumferentially spaced locations around the periphery of the main body portion with each leg opening in the main body portion and including an annular downwardly extending side wall and a bottom wall; and a lower sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the lower sheet main body portion at circumferentially spaced locations around the periphery of the lower sheet main body portion with each lower sheet leg opening in the lower sheet main body portion and including an annular downwardly extending side wall and a bottom wall; the upper sheet being positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet main body portion to define a twin sheet platform structure for the pallet; the lower sheet further including a tower structure extending upwardly from the lower sheet main body portion in surrounding relation to the side wall of each upper sheet leg with each tower structure comprising a plurality of spaced vertical pins upstanding from the lower sheet main body portion in surrounding relation to the side wall of the respective upper sheet leg; each pin including a top wall fused to the under face of the upper sheet main body portion and an annular side wall fused to the annular side wall of the respective upper sheet leg. AMENDED CLAIMS [received by the International Bureau on 5 April 1999 (05.04.99); new claims 17 and 18 added; remaining claims unchanged (2pages)] 17. A twin sheet pallet including an upper sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the main body portion at spaced locations with each leg opening in the main body portion and including an annular downwardly extending side wall and a bottom wall, and a lower sheet thermoformed to define a planar main body portion and a plurality of legs extending downwardly from the lower sheet main body portion at spaced locations with each lower sheet leg opening in the lower sheet main body portion and including an annular downwardly extending side wall and a bottom wall, the upper sheet being positioned in overlying relation to the lower sheet with each upper sheet leg nestingly received in and fused to a respective lower sheet leg and the upper sheet main body portion spaced above the lower sheet main body portion to define a twin sheet platform structure for the pallet, characterized in that: the lower sheet further includes a plurality of spaced vertical pins upstanding from the lower sheet main body portion in a closed loop annular pattern and each including an annular side wall and a top wall fused to the under face of the upper sheet main body portion; the upper sheet defines an annular downturned portion formed in a closed loop annular pattern corresponding to the closed loop annular pattern of the pins; the pins and the downturned portion of the upper sheet are positioned in surrounding concentric relation with respect to each other; and the side wall of each pin is fused to a confronting section of the downturned portion of the upper sheet to form a rigid annular structure . 18. A pallet according to claim 17 wherein: the annular downturned portion of the upper sheet is constituted by an upper region of the annular downwardly extending side wall of one of said upper sheet legs ; and the pins extend upwardly from the lower sheet in surrounding relation to the upper region of the annular side wall of said one upper sheet leg.

Inventors: SHUERT LYLE H, SHUERT, LYLE, H.
Applicants: SHUERT LYLE H, SHUERT, LYLE, H.
Application year: 1998
Main classification: A47B91
IPC codes: B65D19