Patent Abstract:
A nestable pallet includes an upper deck from which a plurality of feet extend downwardly. The upper deck includes an upper planar member and cross-ribs extending downwardly therefrom. The pallet is sturdy yet light weight and can be optionally provided with a reinforcement sheet secured to the lower ends of the ribs to provide a stronger, stiffer pallet.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This is a continuation of U.S. Ser. No. 11/763,988, filed on Jun. 15, 2007. 
     
    
     BACKGROUND 
       [0002]    This invention relates to a nestable pallet for storing or transporting goods. Pallets are often used to store and transport goods. The pallets maintain the goods at a distance above the floor such that they can be readily lifted and moved by a fork of a lift truck. Some pallets have stringers or double decks forming openings which receive the forks of the lift truck. Other pallets are nestable within one another to facilitate storage and transport when empty. Generally, nestable pallets typically have openings in their upper surface, which receive corresponding shaped feet of a similar nestable pallet. Thus, the nestable pallets occupy less space for storage and transport when empty. 
         [0003]    Depending on the type of goods that are being transported, sometimes a pallet with greater strength and stiffness is required. Other times, for storing and shipping lighter goods, a lighter weight pallet would be desirable. Currently pallets of different weights and strengths are made in different molds, which increases cost. 
       SUMMARY 
       [0004]    The present invention provides a nestable pallet with an optional welded bottom. The pallet includes an upper deck and feet extending downward therefrom. The upper deck includes an upper planar member. A plurality of cross-ribs are formed on the under side of the planar member to reinforce the upper surface of the upper deck. The feet are generally hollow and open upwardly, such that they can receive nested therein corresponding feet of a similar container stacked thereon when empty. This provides a light weight pallet. 
         [0005]    An optional welded bottom can be secured to the ribs of the upper deck. The welded bottom may be a lower planar member, such as an injection molded flat sheet. The planar member includes openings through which the feet are inserted. The planar member is then secured to the outer ends of the ribs, such as by vibration welding or hot plate welding. Alternatively, adhesives or other types of bonding could be utilized. 
         [0006]    Thus, a single pallet can be provided in two different variations, with or without the welded bottom. The pallet can be provided in the light weight version without the welded bottom, or the stronger, stiffer pallet with the welded bottom. 
         [0007]    These and other features of the application can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of a pallet according to one embodiment of the present invention. 
           [0009]      FIG. 2  is a bottom perspective view of the pallet of  FIG. 1 . 
           [0010]      FIG. 3  is a bottom view of the pallet of  FIG. 1 . 
           [0011]      FIG. 4  is an exploded view of the pallet of  FIG. 1  with an optional reinforcement sheet. 
           [0012]      FIG. 5  is a top view of the pallet and reinforcement sheet of  FIG. 4 . 
           [0013]      FIG. 6  is a side view of the pallet of  FIG. 4 . 
           [0014]      FIG. 7  is a section view taken along line  7 - 7  of  FIG. 5 . 
           [0015]      FIG. 8  is an end view of the pallet of  FIG. 4 . 
           [0016]      FIG. 9  is a section view taken along line  9 - 9  of  FIG. 5 . 
           [0017]      FIG. 10  is a bottom view of the assembled pallet of  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    A pallet  10  according to one embodiment of the present invention is shown in  FIG. 1 . The pallet  10  includes an upper deck  12  down from which extend a plurality of feet  14   a - d , including corner feet  14   a , end feet  14   b , side feet  14   c  and a center foot  14   d  (unless otherwise more specifically referenced, the referenced numeral “ 14 ” used below will refer to all of the feet  14   a - d ). 
         [0019]    Each of the feet  14  has defined therein a recess opening upwardly for receiving a corresponding foot of a similar container nested therein. The upper deck  12  includes an upper planar member  18  through which the openings  16  and the feet  14  are also defined. Handle openings  20  also extend through the upper planar member  18  of the upper deck  12 . 
         [0020]    Referring to  FIG. 2 , the upper deck  12  includes an upper planar member  18  from which extend a plurality of cross-ribs  24 . The ribs extend in an intersecting pattern on the bottom of the deck  12 . A peripheral rib  26  extends about the periphery of the container  10 . Outside the peripheral rib  26 , a plurality of tapered ribs  28  form a champfer, thus facilitating lifting the pallet  10  with a forklift.  FIG. 3  is a bottom view of the pallet of  FIG. 2 . 
         [0021]      FIG. 4  is an exploded view of the pallet  10  with an optional reinforcement sheet  30 . The reinforcement sheet  30  is an injection molded thermoplastic, but other materials and other manufacturing techniques could also be utilized. The sheet  30  includes a plurality of openings  32 , each corresponding to one of the feet  14 . The sheet  30  further includes a plurality of openings  34  aligning with the handles  20  of the upper deck  12 . The sheet  30  further includes a plurality of small apertures  36  for drainage. 
         [0022]    When increased strength and stiffness of the pallet  10  is desirable, the sheet  30  is vibration welded to the ribs  24  ( FIG. 2 ) of the upper deck  12 . 
         [0023]      FIG. 5  is a top view of the pallet  10  of  FIG. 4 .  FIG. 6  is a side view of the pallet  10 . 
         [0024]      FIG. 7  is a section view taken along line  7 - 7  of  FIG. 5 . As shown, the reinforcement sheet  30  is secured to the ribs  24  of the upper deck  12 . This creates box beam sections in the upper deck  12 . This significantly increases the strength and stiffness of the upper deck  12 . 
         [0025]      FIG. 8  is a front view of the pallet  10 .  FIG. 9  is a section view of the pallet  10  and reinforcement sheet  30  taken along line  9 - 9  of  FIG. 5 . The reinforcement sheet  30  is vibration welded to the ribs  24 , which extend perpendicular to one another in the upper deck  12 . This creates the box beam sections. 
         [0026]      FIG. 10  is a bottom view of the pallet  10  with the reinforcement sheet  30  secured thereto. The feet  14  are received within the openings  32  in the sheet  30 . The center foot  14  is completely circumscribed by the center opening  32 , while the side feet  14   c  are partially circumscribed (more than 180 degrees, but less than 360 degrees), and the corner feet  14   b  are circumscribed less than 180 degrees. Further, the openings  34  align with the handle openings  20 . The apertures  36  provide drainage to the box beam sections, i.e. the cavities defined among the upper planar member  18  (FIG.  1 ,) the cross-ribs  24  ( FIG. 2 ) and the reinforcement sheet  30  (“lower planar member”). 
         [0027]    The pallet  10  can thus be easily provided in two versions, one with the reinforcement sheet  30 , or alternatively without the reinforcement sheet  30 , to provide either a stronger, stiffer pallet  10  or a lighter pallet  10 . 
         [0028]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers for steps in method claims are for ease of reference in dependent claims and do not signify a required sequence unless otherwise stated.

Technology Classification (CPC): 1