Patent Publication Number: US-6216609-B1

Title: Structural channel pallet

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 60/101,450 filed Sep. 15, 1998. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     FIELD OF THE INVENTION 
     The field of the invention is pallets, and more particularly, injection molded plastic pallets having structural hollow channels. 
     BACKGROUND OF THE INVENTION 
     Plastic pallets are in common use in many industries. They are used as load platforms for easily transporting loads using material handling equipment, such as fork lift trucks and the like. A typical pallet has a deck with an upper surface for supporting a load and a lower surface which is engaged by the material handling equipment when in transit. 
     The load on a typical pallet causes the pallet deck to deflect concave upward in the areas between the feet and to compress the feet of the pallet, while lifting or transporting the pallet by engaging the material handling equipment causes the pallet deck to deflect concave downward. Constant movement of the pallet subjects a pallet deck to a continuous cycle of upward and downward deflections, weakening the pallet structure and eventually causing the pallet to fail. 
     One method which prolongs the life of a plastic pallet is to add material to the structural components of the pallet increasing the pallet stiffness and capability to withstand many deflection cycles. This method, however, increases the weight and cost of the pallet. 
     Plastic pallets have in general been made by either rotational molding, single of twin sheet vacuum thermoforming, or injection molding. Rotational molding and vacuum thermoforming can be used to create voids within the pallets, but also results in thin walled sections of relatively low strength. Injection molding is capable of forming thicker walled sections and solid reinforcing ribs resulting in a pallet of solid material with less strength than what the same volume of material is capable of. Thus, a need exists for a method of increasing the strength of material handling pallets, without increasing the weight or cost. 
     SUMMARY OF THE INVENTION 
     The present invention provides an injection molded structural channel pallet having improved structural integrity without adding material to increase the pallet weight. The pallet has a deck having a top and a bottom, and a number of feet are formed extending downwardly from the deck. Ribs define an open grid pattern in the deck, and hollow channels are formed in the deck, which increases the strength of the pallet, without disproportionately increasing the volume of weight of material used. The hollow channels are formed at strategic locations on the top and the bottom of the deck. 
     A general objective of the present invention is to provide an injection molded plastic pallet having increased strength, while reducing its weight and volume of material used in comparison to a solid pallet of the same capacity or exterior dimensions. This objective is accomplished by forming hollow channels at strategic locations in the pallet deck. In one embodiment the hollow channels strategically define substantially identical patterns in pallet quadrants defined by a pallet longitudinal and lateral axis. Each channel pattern has primary channels. One primary channel extends along a diagonal across the quadrant. Secondary channels may branch off of at least one of the primary channels. 
     Another objective of the present invention is to reduce pallet deflection when the pallet is supporting a load or being lifted by material handling equipment. This objective is accomplished by providing hollow channels in a pattern which cross over between the pallet deck top and bottom. 
     Yet another objective of the present invention is to provide a pallet with strengthened feet to support the pallet deck, and increase the pallet load capacity. This objective is accomplished by forming hollow channels around the feet top and down along the feet sides. In one embodiment, the primary channels in the pattern encircle the tops of the pallet feet, and are formed in the corners of convolutions in the feet sides. 
     The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top plan view of a pallet incorporating the present invention; 
     FIG. 2 is a bottom plan view of the pallet of FIG. 1; 
     FIG. 3 is a transparent plan view of a pallet incorporating the present invention; 
     FIG. 4 is a transparent end view of FIG. 1; 
     FIG. 5 is a section view along line  5 — 5  of FIG. 1; 
     FIG. 6 is a transparent side view of FIG. 1; 
     FIG. 7 is a section view along line  7 — 7  of FIG. 1; 
     FIG. 8 is detail view B—B of FIG. 7; 
     FIG. 9 is detail view C—C of FIG. 7; 
     FIG. 10 is a section view along line  10 — 10  of FIG. 12B; 
     FIG. 11 is a section view along line  11 — 11  of FIG. 4; 
     FIG. 12A is an enlarged fragmentary view of a single quadrant of the pallet, illustrated as if the pallet was transparent; 
     FIG. 12B is a view like FIG. 12A, but is a top view showing the quadrant opaque and not showing hidden lines; 
     FIG. 13 is a section view along line  13 — 13  of FIG. 1; 
     FIG. 14 is a section view along line  14 — 14  of FIG. 1; 
     FIG. 15 is a section view along line  15 — 15  of FIG. 1; and 
     FIG. 16 is a section view along line  16 — 16  of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1-9, a structural channel pallet  10  has a deck  12  with a top  14  and a bottom  16 . The deck  12  is supported by a plurality of feet  18 ,  20 ,  22 ,  24  which are integrally formed as part of the deck  12 . When supported by the feet, the deck top  14  supports a load (not shown) which causes the deck  12  to deflect convex downward, increasing the tensile stress in the deck bottom  16 . Conversely, the pallet  10  is lifted using material handling equipment, such as a fork lift, engaging the deck bottom which deflects the deck  12  to take on a convex upward shape, causing tensile stress in the deck top  14 . Structural channels  17 ,  19 , more clearly shown in FIGS. 12A and 12B, formed in the deck top  14  and bottom  16 , and feet  18 ,  20 ,  22 ,  24  increase the structural integrity of the pallet  10  without increasing the pallet weight. 
     Referring to FIG. 1, the pallet  10  is generally rectangular having a longitudinal axis  26 , a lateral axis  28 , and two opposing sides  30 ,  34  joined together by two opposing ends  32 ,  36 . The pallet  10  is formed from by injection molding thermoplastic material, such as polyethylene, using a molding method which forms channels in the thermoplastic materials, such as the injection molding techniques described in U.S. Pat. Nos. 4,498,860; 4,740,150; 4,824,732; 4,923,666; 4,923,667; and 5,770,237, which are hereby incorporated by reference. Other methods known in the art to form hollow channels may be used, such as inserting pins in the molten material or the like, without departing from the scope of the present invention. 
     The pallet  10  has a total of nine feet supporting the deck  12 ; four corner feet  18 , one at each pallet corner  43 ; two side feet  20 , one on each pallet side  30 ,  34  disposed between adjacent corner feet  18 ; two end feet  22 , one on each pallet end  32 ,  36  disposed between adjacent corner feet  18 ; and one center foot  24  generally located at the intersection of the longitudinal and lateral axes  26 ,  28 . Looking particularly at FIGS. 4-7, each foot  18 ,  20 ,  22 ,  24  is cup shaped having an open top  38  formed at the deck top  14 , and extends through the deck bottom  16  for engagement of a supporting surface by the foot bottom  40 . The open feet tops  38  receive the feet bottoms of a like configured stacked pallet. Fins  42  formed in the feet bottom  40  support the stacked pallet and maintain a vertical separation between stacked pallets when the feet of an upper pallet are nested within the feet of a lower pallet. 
     Referring to FIG. 1, the pallet corner feet  18  support the pallet corners  43  and are generally trapezoidal shaped having four sides  44 ,  46  and rounded corners  51 . First and second sides  44  are spaced apart and substantially parallel to the pallet longitudinal axis  26 . The third and fourth sides  46  are spaced apart joining the first and second sides  44  at an angle for guiding lift equipment, such as lift truck forks, into a space  49  (shown in FIGS. 4-7) between a corner foot  18  and an adjacent side foot  20 ,  22 . Convolutions  48  in each corner foot side  44 ,  46  enhance the load carrying capacity of each foot  18 . 
     Two side feet  20  formed at each side  30 ,  34  are generally D-shaped having an inner side  50  substantially parallel to the longitudinal axis  26 , and a curved side  52  bulging outward away from the center foot  24 . The curved side  52  of the foot  20  guides lift equipment into the space  49  between the side foot  20  and an adjacent corner foot  18 . Each side  50 ,  52  of each side foot  20  has a convolution  60  strengthening the bearing capacity of the foot  20 . 
     Two end feet  22  are generally bullet shaped having an inner side  62  substantially parallel to the lateral axis  28 , a pair of spaced sides  64  substantially parallel to the longitudinal axis  26  and joined by the inner side  62 , and a nose  66  pointing outward away from the center foot  24 . The nose  66  guides lift equipment into the space  49  between the end foot  22  and an adjacent corner foot  18 . Each of the spaced sides  64  and the nose  66  have a convolution  72  strengthening the bearing capacity of the foot  22 . 
     The center foot  24  is generally square having four sides  74 , and centrally located in the pallet  10  at the intersection of the longitudinal and lateral axes  26 ,  28 . Each side  74  is approximately at a 45 degree angle to each axis  26 ,  28  and has a convolution  72  strengthening the bearing capacity of the foot  24 . 
     Looking particularly at FIG. 3, the pallet deck  12  is a grid  76  formed of a plurality of spaced ribs  78 ,  80  and an edge portion  54  integrally formed around the circumference of the grid  76 . Preferably, the grid  76  is formed by a set of nineteen longitudinal ribs  78  which are substantially parallel to the longitudinal axis  26  and a set of twenty-three lateral ribs  80  perpendicular to the longitudinal ribs  78  and substantially parallel to the lateral axis  28 . The intersecting ribs  78 ,  80  define grid squares  82 . 
     Looking particularly at FIGS. 5 and 7, the ribs  78 ,  80  are substantially narrower in width than in depth having upper edges  84  and lower edges  86 . The upper edges  84  are substantially coplanar and define the deck top  12  and the rib lower edges  86  are substantially coplanar defining the deck bottom  16 . 
     Referring to FIG. 2, structural flanges  88  formed on the rib upper edges  84  encircling the center foot  24  define a square shape. The structural flanges  88  help resist tensile elongation of the ribs  78 ,  80  around the center foot  24 , for example when picking up the pallet with a fork lift. Additional structural flanges  92  formed on the rib upper edges  84  encircling the feet  18 ,  20 ,  22 , and  24  strengthen the deck  12  around the feet  18 ,  20 ,  22  and  24 . Structural flanges  94  along rib lower edges  86  of ribs adjacent to bottom holes  96  strengthen the ribs  78 ,  80 . 
     As shown in FIGS. 1-3, crossover flanges  98  formed along rib faces  100  crossover from upper structural flanges  88  to lower structural flanges  94  and vice versa. The crossover flanges  98  provide additional structural integrity to the ribs  78 ,  80 , and also make the upper and lower structural flanges  88 ,  94  continuous with one another, which assists in supporting tensile and also compressive loads on the flanges. Referring to FIG. 12B, the crossover flanges  98  occur at positions between, and run in the direction that extends between, two adjacent feet, so as to position the lower flanges  94  in the squares  82  which are approximately midway between the two adjacent feet. This creates a pattern in the pallet  10 , with the laterally running lower flanges  94  and their corresponding crossovers  98  centrally positioned along axes  181  and  183  (FIG. 1) and the longitudinally running lower flanges  94  and their corresponding crossovers  98  centrally positioned along axes  185  and  187 . 
     All crossovers, including the channel crossovers described below, are positioned along one (or two in the case of diagonal channel  128 ) of the axes  181 ,  183 ,  185  and  187 . The crossover flanges  98  and corresponding lower flanges  94  which they run into are positioned in the area between the feet, and one to two squares to each side of the area which is directly between the feet. As such, the flanges  94  are on nearly every rib  78  or  80  along the respective axes  181 ,  183 ,  185  and  187 . However, where two of the axes  181 ,  183 ,  185  and  187  cross, in the square centered on the intersection of the two axes which has its corners defined by the outer corners of the squares  82  in which the channel crossover  154  and  155  occur (discussed below with reference to FIG.  12 B), the only crossovers  98  are adjacent to the other two corners of the square, i.e., adjacent to the gates  110  and  114 . Within this 3×3 square, which contains the nine squares  82  (3×3) which together are centered on each intersection of two crossover axes (with corners at gates  108 ,  110 ,  112  and  114 ), there is a concentration of lower flanges  94  for improved load carrying ability when the pallet is supported by the feet. 
     As shown in FIG. 12B, the crossover flanges  98  and corresponding lower flanges  94  associated with the pairs of adjacent feet are on the rib  78  or  80  outside of the aforementioned square, along the respective crossover axes  181 ,  183 ,  185  and  187 . In addition, the holes  96  for the lower anti-skid grommets (not shown) for supporting the pallet  10  on fork lift forks are formed just outside of the 3×3 square. 
     Looking particularly at FIGS. 7-9, hollow channels  17 ,  19  which are part of a pattern  104 , shown in FIG. 12 by respective short and long dashed lines, in each of four deck quadrants  106 . The hollow channels  17 ,  19  increase the structural integrity of the pallet  10  without increasing the pallet weight. The channels  17 ,  19  define the pattern  104  on the deck top  14  and bottom  16 . Each of the corner quadrants  106  is defined by the longitudinal axis  26  and lateral axis  28  intersecting at the deck center  107 . The quadrants  106  are substantially identical to one another, being either the same as or mirror images of one another (diagonally opposite quadrants are the same, adjacent quadrants are mirror images of one another). Thus, the pattern  104  of channels  17 ,  19  in each quadrant  106  is identical in each of the four quadrants  106  of the deck grid  76 . Referring to FIGS. 12A and 12B, each quadrant  106  preferably has six gates  108 ,  110 ,  112 ,  114 ,  116 , and  118  for injecting the thermoplastic material into the mold. The gates  108 ,  110 ,  112 ,  114 ,  116 , and  118  are spaced along the deck top  14  in a rectangular pattern ensuring an even distribution of thermoplastic material in each quadrant  106 . In the preferred embodiment, one gate  108 , nearest the center foot  24  and disposed along a diagonal  120  extending from the center foot  24  to the corner foot  18  in the quadrant  106 , also injects gas in to the thermoplastic material forming the structural channels  17 ,  19 , such as described in U.S. Pat. Nos. 4,498,860, 4,740,150, 4,824,732, 4,923,666, 4,923,667, and 5,770,237, referred to above. The gas injecting gate  108  defines the start of the channel pattern  104  in each quadrant  106 . 
     Each channel pattern  104  has four primary channel legs  122 ,  124 ,  126 ,  128 , illustrated with short dashed lines. From the area of the gate  108 , each primary channel leg  122 ,  124 ,  126  and  128  extends toward a respective foot  24 ,  20 ,  22 , or  18  at each corner of the quadrant  106 . The cross-sectional shape of a primary channel  17  is shown in FIG.  8 . Secondary channels  19 , illustrated with longer dashed lines, run along the upper or lower edges  84 ,  86  of certain ribs  78 ,  80  which branch off of the primary channel leg  128 . The cross-sectional shape of a secondary channel  19  is shown in FIG. 9, and has a significantly smaller open area than a primary channel  17 . Accordingly, the primary channels  17  strengthen the pallet  10  more than the secondary channels  19 . 
     Referring to the pattern  104  of primary and secondary channels  17 ,  19  indicated by respective short and long dashed lines in a single quadrant  106 , as shown in FIGS. 12A and 12B, a first primary channel leg  122  extends along the diagonal  120  from the gas injecting gate  108  at the deck top  14  toward the center foot  24 . The channel leg  122  extends around one-quarter of the center foot top  38  and down both corners  130  of a convolution  72  disposed within the quadrant  106 . The legs  122  of the three other quadrants  106  also extend around their respective one-quarters of the top of the center leg  24  (and into the corners of the respective convolutions) so all the legs  22  communicate with one another at the top of the center leg  24 . As in the ribs  78 ,  80 , the hollow channels in the convolution corners  130  increase the structural integrity of the convolutions  72  without increasing the pallet weight. 
     A second primary channel leg  124  extends from the gas injecting gate  108  along the first primary channel leg  122  at least one grid square  82  toward the deck center foot  24 . The second primary channel leg  124  then generally proceeds past one square  82  along the upper edge  84  of a lateral rib  80  to a first crossover subchannel  134  of the channel  124  which extends from the rib upper edge  84  to the rib lower edge  86  (FIG. 12B) to a lower subchannel  137 . The cross sections of the channel  124  in this area is the same as for channel  126  as shown in FIGS. 13 an  14 . Sub channel  137  extends along the lateral rib lower edge  86  past one full square  82  to a second crossover subchannel  136  of the channel  124  which extends from the rib lower edge  86  to the rib upper edge  84 . The leg  124  then proceeds toward the deck side  34 . Two channel extensions  138  along longitudinal ribs  78  extend from the second leg  124  to a channel  140 , shown in FIG. 10, encircling approximately half of the adjacent side foot top  38  and down the two side foot convolution corners  142 , shown in FIG. 11, which are disposed within the quadrant  106 . The hollow channel extends all the way around the top of the foot  20 , and other half of the channel being in the adjacent quadrant  106 . 
     As shown in FIGS. 13 and 15, the first and second crossover channels  134 ,  136  define a primary channel path from the deck top  14  to the deck bottom  16  and back to the top  14 . By routing the hollow channel  124  on both the top  14  and bottom  16  of the pallet deck  12 , pallet deflection is minimized when the pallet  10  is supporting a load or being lifted by material handling equipment. 
     A third primary channel leg  126  extends from the gas injecting gate  108  along the first primary channel leg  122  at least one grid square  82  toward the deck center foot  24 . The third primary channel leg  126  then generally proceeds past one grid square  82  along the upper edge  84  of a longitudinal rib  78  to a first crossover subchannel  144  (FIGS. 12B,  13  and  15 ) of the channel  126  which extends from the rib upper edge  84  to the lower edge  86  and into subchannel  133  of channel  126 . Subchannel  133  then extends along the lower edge  86  of the longitudinal rib  78  past one full square  82  to a second crossover subchannel  146  of the channel  126  which extends from the rib lower edge  86  to the rib upper edge  84 . The channel leg  126  can generally proceeds toward the deck end  36 . Two channel extensions  148  extend along upper edges  84  of lateral ribs  80  from the third leg  126  to a channel  150  encircling half of the adjacent end foot top  38  and down the three foot convolution corners  152  within the quadrant  106 . 
     A fourth primary leg channel  128  extends from the injecting gate  108  along the diagonal  120  toward the deck corner foot  18  within the quadrant  106  into a crossover subchannel  154  of the channel  128  which extends from the deck top  14  to the deck bottom  16  along the diagonal  120  and into subchannel  127 . Subchannel  127  extends along the diagonal  120  on the deck bottom  16  diagonally across the square  82  which is at the intersection of the two crossover axes ( 183  and  187  in FIG. 12B) which run through the quadrant to a second crossover subchannel  155  of the channel  128  which extends from the deck bottom  14  to the deck top  16 . 
     Referring to FIG. 12B, in each square  82  in which primary channel  128  crosses over from top to bottom (i.e., in the squares  82  that contain crossovers  154  and  155 ), a protective web  153  (FIG. 12B) of plastic material extends from top to bottom diagonally across the square. The channels  154  and  155  extend through each web  153  relatively low in the square, so the web  153  covers the channel  154  or  155  at the upper reaches of the channel  154  or  155 . Each web  153  defines holes  173  adjacent to their lower sides next to lower flanges  94 , which permit drainage out of the square. 
     As shown in FIGS. 14 and 16, the first and second crossover channels  154 ,  155  define a primary channel path from the deck top  14  to the deck bottom  16  and back to the top  14  along the diagonal  120 . As in the other crossover channels, by routing the hollow channel  128  on both the top  14  and bottom  16  of the pallet deck  12 , pallet deflection is minimized when the pallet  10  is supporting a load or being lifted by material handling equipment. 
     Secondary channels  19  branching off of the fourth primary channel leg  128  extend along the longitudinal and lateral ribs  78 ,  80  toward the pallet side  34  and end  36  in the quadrant  106 . Each secondary channel  19  remains on the upper or lower rib edge  84 ,  86  on which it originated from the fourth primary channel leg  128 . The fourth leg  128  terminates encircling the corner foot  18  at  159  and extending down the corners  156  of each convolution  48  in the corner foot  18 . 
     Additional secondary channels may also be formed in the structural flanges  88 ,  92  along the upper edges  84  of the longitudinal and lateral ribs  78 ,  80  between the quadrants  106 . The invention may be practiced without any secondary channels  19 , but if they are provided, they further increase the pallet  10  strength without providing additional material which increases the pallet weight. If the gas charging method of forming the channels is used, the secondary channels will typically be of varying length (depending on processing conditions) and not necessarily continuous or joining with the secondary channels of adjacent quadrants. 
     Referring to FIGS.  1 — 4 , the pallet deck has an edge portion  4  formed by edge ribs  162  supporting a skirt  158  around the pallet deck  12  periphery. Edge ribs  162  extending outward from the grid  76  periphery supports the skirt  158  and a skin  160 . A skin  160  formed on the deck top  14  extends inward from the pallet sides  30 ,  34 , and ends  32 ,  36  toward the pallet center  161  covering the edge ribs and the outermost grid squares  162  of the rib grid  76 . The skin  160  strengthens the pallet sides  30 ,  32 ,  34 ,  36  and the grid  76  around the corner and side feet  18 ,  20 ,  22 . Auxiliary ribs  164  bisect the skin covered squares  162  providing additional support for the skin  160 . 
     Holes  96 ,  168  for securing an anti-skid rubber grommet (not shown) on the top or bottom of the pallet deck  12  are spaced about the deck top  14  within the area defined by the skin  160  and within grid squares  82  at the deck bottom  16 . Preferably, four top holes  168  are spaced along each pallet side  30 ,  32 ,  34 ,  36  disposed within the area covered by the skin  160  for a total of sixteen top holes  168 . Four additional bottom holes  96  in each quadrant  106 , two disposed on opposite sides of the channel diagonal  120 , are formed in the area defined by grid squares  82  at the deck bottom  16 , providing a total of sixteen bottom holes  96  for the entire pallet  10 . A grommet attachment hole  97  is also provided in each foot. Grommets provided in the feet keep the pallet from sliding around on the floor, grommets in the bottom of the deck in the fork passages keep it from sliding around on top of fork lift forks, and grommets provided on the upper surface of the deck keep the load, i.e., plastic boxes filled with components, from sliding around. 
     Thus, there has been described, and shown in FIGS. 1-16, an injection molded plastic pallet  10  having hollow structural channels  17 ,  19  formed in it in a manner which increases its strength, while reducing its weight and the volume of plastic material used in comparison to a solid pallet of the same capacity or exterior dimensions. The hollow structural channels  17 ,  19  in some areas of the pallet  10  run along the top surface  14  of the pallet deck  12 , and in other areas, run along the bottom surface  16  of the pallet deck  12 . In particular, as a hollow channel  17  traverses a quadrant  106 , either longitudinally, laterally or diagonally, the channel  17  crosses over from the deck top  14  to the deck bottom  16  when it enters a central zone of the quadrant  106 , and crosses back to the deck top  14  when it exits the central zone, as it continues across the quadrant  106 . The central zone of the quadrant  106  being defined as the zone between the feet  18 ,  20 ,  22 ,  24  at each corner of the quadrant  106  defining an X centrally disposed in the quadrant  106 . For example, in FIG. 12B, the hollow channels  17  crossover between the top and bottom of the pallet where they cross the axes  183 ,  187 , in the central zone of the quadrant. The secondary channels  19  adjacent to the lateral and longitudinal channels  17  also cross over between the pallet top and bottom where they cross the axes  183 ,  187 . 
     Solid structural flanges  88 ,  94  on either one or both sides of the ribs  78 ,  80  that make up the deck grid  76  can also be made to cross over from the deck top  14  to the deck bottom  16  and then back to the deck top  14  when they cross either longitudinally or laterally the quadrant central zones between adjacent feet, including for a small distance (e.g., 1-2 squares) to the sides of the two adjacent feet. These flanges  88 ,  94  can be formed on the hollow channels  17 ,  19  as well so as to run along the outer side of the channel  17 ,  19 , i.e., on top of the channel when the channel is on deck top  14 , and along the bottom of the channel when the channel runs along the deck bottom  16 . 
     The high tensile stress areas at the deck bottom  16  between pallet feet are fortified by the channels  17 ,  19  and flanges  94  running along the deck bottom  16 . This fortification is of particular benefit when the feet are supporting the pallet deck  12 . In addition, the channels  17 ,  19  (and solid flanges  88 ) at the deck top  14  in the areas outside of the central zones (the central zones being directly over the center of the fork lift fork passages defined by the feet under the pallet) serve to reinforce these areas against tensile stress which is experienced when the pallet  10  is picked up by a fork lift. 
     All of the four corner quadrants  106  of the preferred embodiment are identical, with four primary channel legs  122 ,  124 ,  126  and  128  provided in each quadrant  106 . Each primary channel leg  122 ,  124 ,  126 , and  128  is a primary channel  17  which runs to a different one of the four feet that are at least partially included in the quadrant  106 . The primary channels legs  122 ,  124 ,  126 , and  128  cross over from the deck top  14  to the deck bottom  16 , and back to the deck top  14 , as described above, in the central zones. 
     In each quadrant  106 , two of the primary channel legs  122 ,  128  run along a diagonal  120  between the pallet center foot  24  and the pallet corner foot  18 , and are coterminous with one another. Another primary channel leg  124  branches off from the diagonal primary channel  122  and extends laterally to the vicinity of one of the two side/end feet  20 ,  26  of the quadrant  106 , and another primary channel leg  126  branches off from the same point on the diagonal channel  122 , and extends longitudinally to the vicinity of the other of the two side/end feet  20 ,  26  of the quadrant  106 . Each of the primary channel legs  124 ,  126  that leads to a side or end foot  20 ,  26  is joined to a channel  140 ,  150  that surrounds the top of the side or end foot  20 ,  26  by two branch channels  138 ,  148 , which run orthogonally to the primary channel leg  124 ,  126 . 
     The hollow channels (e.g.,  140  in FIG. 10) surrounding the top of each of all nine of the feet of the pallet are connected to one or more primary channel legs from each of the four quadrants  106 . The hollow channel  159  surrounding each corner foot  18  has a single primary channel leg  128  leading into it. The hollow channel  140  surrounding each side foot  20  has two primary channel legs  124  leading to it, one from each adjacent quadrant  106 . The hollow channel surrounding the center foot  24  has four primary channels  122  leading to it, one from each of the four corner quadrants  106  of the pallet  10 . 
     Each pallet foot (e.g.,  22 ) is formed with convolutions (e.g.,  72 ) which run up and down the foot side. The convolutions are indents or ridges in the side of the foot which define corners. Each convolution corner has a hollow channel (e.g.,  152 , FIG. 11) running through it which opens into the top channel  140  which surrounds the foot, and which further reinforces the load carrying ability of the foot. This is accomplished without the channel defining a distinct exterior shape indicative of a channel, since it is formed in the corner of the convolution. 
     While there has been shown and described the preferred embodiment of the invention, it will be obvious to those skilled in the art that various changes and modifications can be made therein without departing from the spirit of the invention.