Patent Description:
Retail stores often prefer the use of fractional pallets when displaying products that are for customer purchase. Fractional pallets are typically one-quarter to one-half the size of full size pallets. Fractional pallets have a significantly smaller footprint, which allows retail stores to display a greater variety of products within the same size area as full size pallets.

In addition, retail stores often prefer the use of fractional plastic pallets instead of fractional wood pallets. Fractional plastic pallets are more aesthetically pleasing than fractional wood pallets, as well as being more sanitary.

Even in view of current fractional plastic pallets, there is still a need for a fractional plastic pallet that can be easily moved by pallet handling equipment and can enable product display that is aesthetically acceptable. Since the products to be carried by the fractional plastic pallet at times may be relatively heavy, the load carrying capacity of the pallet should not be sacrificed while also providing accessibility.

<CIT> discloses a pallet including a deck, a support structure for supporting the deck above the ground, and a plurality of retractable wheels that can be configured in a deployed condition in which they fully support the pallet or a retracted condition. <CIT> discloses that a releasable locking mechanism is provided for locking the retractable wheels in the deployed condition.

According to a machine translation of <CIT>, <CIT> discloses a removable and transformable pallet structure.

According to a machine translation of <CIT>, <CIT> discloses a synthetic resin pallet having a space for fitting a fixation tool formed on the upper deck of the synthetic resin pallet.

According to a machine translation of <CIT>, <CIT> discloses a pallet having plurality of surface side anti-skid parts which are protrusively provided upward on a surface of the pallet.

A first aspect of the present invention is directed to a reconfigurable pallet/dolly platform according to claim <NUM>. The reconfigurable pallet/dolly platform includes a top deck including a product support surface and an opposing underside. The product support surface includes grommet openings extending therethrough, with each grommet opening including a recessed shelf. The underside includes pallet support leg attachment areas aligned with the grommet openings for receiving pallet support legs when configured as a pallet, and dolly wheel attachment areas for receiving dolly wheels when configured as a dolly. The product support surface includes grommets inserted into the grommet openings. Each grommet includes an upper section comprising an upper lip resting on the recessed shelf, and an outer exposed surface of the upper section extending in height above the top deck to engage an underside of the pallet support legs from an identical platform stacked thereon when configured as a pallet. The product support surface further includes dolly wheel receiving areas aligned with the dolly wheel wells to engage the dolly wheels from an identical platform stacked thereon when configured as a dolly.

The underside of each pallet support leg includes grommet openings, with each grommet opening configured to receive the upper section of a respective grommet of the identical pallet when stacked thereon.

The upper section of each grommet includes an upper surface, with a transition between the upper surface and the upper lip being curved.

The grommet openings of the top deck may be positioned at opposing ends of the top deck, with each opposing end having a pair of spaced apart grommet openings with a pair of grommets inserted therein. Each pallet support leg may include a base extending across a width of the top deck, and a pair of outer base support elements. Each outer base support element has a lower end integrally formed with an end of the base, and an upper end coupled to the underside of the top deck. An underside of the base is configured to engage the upper sections of a pair of grommets of an identical pallet when stacked thereon.

Each pallet support leg may further include a center base support element having a lower end integrally formed with the base, and an upper end coupled to the underside of the top deck. Each pair of spaced apart grommet openings of the top deck includes a respective grommet opening between the center base support element and each outer base support element.

According to the invention, each grommet further includes at least one mid-section adjacent the upper lip and extending from the upper section to an underside of the top deck. At least one lower section extends from the at least one mid-section, and includes a pair of spaced apart lower lips resting on the underside of the top deck. An outer exposed surface of the at least one lower section extends in height below the underside of the top deck.

Each grommet opening may further include a divider, wherein the at least one mid-section may include a pair of spaced apart mid-sections. Each mid-section may be separated by the divider, and wherein the at least one lower section may include a pair of lower sections. Each lower section extends from a respective mid-section.

The divider may include a lower surface even with the underside of the top deck. The divider may include an upper surface that is below the recessed shelf. The top deck and the pallet support legs comprise plastic.

Another aspect is directed to a method for making a reconfigurable pallet/dolly platform according to claim <NUM>. The method includes forming a top deck including a product support surface and an opposing underside. The product support surface has grommet openings extending therethrough. Each grommet opening includes a recessed shelf. The underside includes pallet support leg attachment areas aligned with the grommet openings for receiving pallet support legs when configured as a pallet, and dolly wheel attachment areas for receiving dolly wheels when configured as a dolly. The product support surface includes grommets inserted into the grommet openings. Each grommet includes an upper section comprising an upper lip resting on the recessed shelf. An outer exposed surface of the upper section extends in height above the top deck to engage an underside of the pallet support legs from an identical platform stacked thereon when configured as a pallet. The product support surface also includes dolly wheel receiving areas aligned with the dolly wheel wells to engage the dolly wheels from an identical platform stacked thereon when configured as a dolly.

The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the particular embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

Referring initially to <FIG> and <FIG>, the illustrated half-size plastic pallet <NUM> includes a top deck <NUM>, and removable three pallet support legs <NUM> coupled to the top deck. With the pallet support legs <NUM> being removable from the top deck <NUM>, this allows the half-size plastic pallet to be easily repaired should a pallet support leg <NUM> or the top deck <NUM> becomes damaged.

The three pallet support legs <NUM> include a pair of outer pallet support legs and a center palter support leg. The pallet support legs <NUM> are configured to enable four-way entry by pallet handling equipment, such as a forklift or a pallet jack. As will be discussed in detail below, the plastic pallet <NUM> is repairable, stackable and includes product display attachment points.

The half-size plastic pallet <NUM> is <NUM>,<NUM> by <NUM>,<NUM> (<NUM> inches by <NUM> inches). Even though the disclosed features of the plastic pallet <NUM> are directed to a half-size pallet, these features may be used on other size plastic pallets. The size of the plastic pallet <NUM> may be reduced to quarter-size, for example, which is <NUM>,<NUM> by <NUM>,<NUM> (<NUM> inches by <NUM> inches). The size of the plastic pallet <NUM> may even be increased to full-size, which is <NUM>,<NUM> by <NUM>,<NUM> (<NUM> inches by <NUM> inches). These dimensions may be adjusted to accommodate countries that use the metric system.

The top deck <NUM> includes an upper surface referred to as a product support surface <NUM>, and an opposing lower surface referred to as an underside <NUM>. The top deck <NUM> has outer exposed sides extending between the product support surface <NUM> and the opposing underside <NUM>. The outer exposed sides include spaced apart outer sides <NUM> and spaced apart outer sides <NUM>. Outer sides <NUM> correspond to a length of the half-size plastic pallet <NUM>, and outer sides <NUM> correspond to a width or end of the half-size plastic pallet <NUM>. The length is the longer dimension (i.e., <NUM>,<NUM> (<NUM> inches)) of the half-size plastic pallet <NUM>, whereas the width is the shorter dimension (i.e., <NUM>,<NUM> (<NUM> inches)) of the half-size plastic pallet <NUM>.

The outer pallet support legs <NUM> are aligned with outer sides <NUM>. That is, the outer sides <NUM> are parallel to the pallet support legs <NUM>. Each pallet support leg <NUM> has a length that is the same as the dimensions of outer sides <NUM>. That is, each pallet support leg <NUM> extends across a width of the half-size plastic pallet <NUM>.

Referring now to <FIG>, each pallet support leg <NUM> includes a base <NUM>, and base support elements <NUM>, <NUM> extending from the base <NUM>. The base support elements <NUM>, <NUM> are coupled to the underside <NUM> of the top deck <NUM>. Base support element <NUM> may be referred to as an outer base support element, whereas base support element <NUM> may be referred to as a center base support element. The outer and center base support elements <NUM>, <NUM> are monolithically formed with the base <NUM>.

Each outer base support element <NUM> has a lower end integrally formed with the base <NUM>, and an exposed upper end. A pair of outwardly facing snaps <NUM> extend from the exposed upper end to contact the underside <NUM> of the top deck <NUM>. Similarly, a pair of inwardly facing snaps <NUM> extend from the exposed upper end to contact the underside <NUM> of the top deck <NUM>. The snaps <NUM>, <NUM> are configured to engage snap openings <NUM> in the underside <NUM> of the top deck <NUM> so that the outer base support elements <NUM> are coupled to the top deck <NUM>.

The underside <NUM> of the top deck <NUM> further has a plurality of guide openings <NUM> adjacent the plurality of snap openings <NUM>. Also extending from the exposed upper end of the outer base support element <NUM> is a pair of spaced apart guides <NUM>. The guides <NUM> are configured to align the snaps <NUM>, <NUM> with the snap openings <NUM>. The guide openings <NUM> correspond to a profile or outline of the outer base support element <NUM> that is defined by the outwardly facing side wall <NUM>, the inwardly facing side wall <NUM> and the pair of curved end walls <NUM>. Dimensions of the guide openings <NUM> in the underside <NUM> of the top deck <NUM> are less than dimensions of the profile or outline of the outer base support element <NUM> so as to receive the guides <NUM>.

As illustrated in <FIG>, the snap openings <NUM> for the outwardly facing snaps <NUM> are directed outwards so that they are exposed by the outer sides <NUM> of the top deck <NUM>, whereas the snap openings <NUM> for the inwardly facing snaps <NUM> are directed inwards and are not exposed. A height of the guides <NUM> may be the same as a height of the snaps <NUM>, <NUM>. In other embodiments, the height of the guides <NUM> may be different than the height of the snaps <NUM>, <NUM>.

The outer base support element <NUM> has an outwardly facing side wall <NUM> with the pair of outwardly facing snaps <NUM> extending therefrom, and a spaced apart inwardly facing side wall <NUM> with the pair of inwardly facing snaps <NUM> extending therefrom. The pair of outwardly facing snaps <NUM> are recessed from the outwardly facing side wall <NUM>. The pair of inwardly facing snaps <NUM> are recessed from the inwardly facing side wall <NUM>.

A pair of curved end walls <NUM> is at the ends of the outwardly and inwardly facing side walls <NUM> and <NUM>, with the pair of guides <NUM> extending from the pair of curved end walls <NUM>. A portion of each guide <NUM> is curved corresponding to curvature of the curved end walls <NUM>. The pair of guides <NUM> are recessed from the pair of curved end walls <NUM>.

Each snap <NUM>, <NUM> includes a flexible snap element <NUM>, a lip <NUM> extending outwards from the snap element <NUM>, and an angled face or edge <NUM> between the lip <NUM> and the snap element <NUM>. The angled face <NUM> and lip <NUM> flexible engage a corresponding snap opening <NUM> in the underside <NUM> of the top deck <NUM>.

The center base support element <NUM> has a lower end integrally formed with the base <NUM>, and an exposed upper end. Two pairs of outwardly facing snaps <NUM> extend from the exposed upper end to contact the underside <NUM> of the top deck <NUM>. The snaps <NUM> are configured to engage snap openings <NUM> in the underside <NUM> of the top deck <NUM>. As illustrated in <FIG>, the snap openings <NUM> for the outwardly facing snaps <NUM> are in the underside <NUM> of the top deck <NUM> and are not exposed by either of the outer sides <NUM>, <NUM>.

The underside <NUM> of the top deck <NUM> further has a plurality of guide openings <NUM> adjacent the plurality of snap openings <NUM>. Also extending from the exposed upper end of the center base support element <NUM> are two pairs of spaced apart guides <NUM>. The guides <NUM> are configured to align the snaps <NUM> with the snap openings <NUM> in the underside <NUM> of the top deck <NUM>. The guide openings <NUM> correspond to a profile or outline of the center base support element <NUM> that is defined by wall <NUM>. Dimensions of the guide openings <NUM> in the underside <NUM> of the top deck <NUM> are less than dimensions of the profile or outline of the center base support element <NUM> so as to receive the guides <NUM>.

The center base support element <NUM> is circular-shaped. The two pairs of snaps <NUM> extend from the circular-shaped wall <NUM>, and the guides <NUM> and the snaps <NUM> are recessed from the circular-shaped wall <NUM>. The guides <NUM> and the snaps <NUM> are curved to match the curvature of the circular-shaped wall <NUM>. A height of the guides <NUM> may be the same as a height of the snaps <NUM>. In other embodiments, the height of the guides <NUM> may be different than the height of the snaps <NUM>.

Each snap <NUM> includes a flexible snap element <NUM>, a lip <NUM> extending outwards from the snap element <NUM>, and an angled face or edge <NUM> between the lip <NUM> and the snap element <NUM>. The angled face <NUM> and lip <NUM> flexible engage a corresponding snap opening <NUM> in the underside <NUM> of the top deck <NUM>.

The center base support element <NUM> further includes a core section <NUM> that is ribbed. In addition, the core section <NUM> also extends from the exposed upper end. A height of the core section <NUM> is less than a height of the snaps <NUM>.

Each pallet support leg <NUM> is identical to one another. The base <NUM> in each pallet support leg <NUM> includes an opening <NUM> for receiving a reinforcement bar. A reinforcement bar adds strength and durability to the pallet support leg <NUM>. The reinforcement bar may be, but is not limited to, steel or metal, for example. The base <NUM> includes spaced apart openings <NUM> that expose the reinforcement bar. After a reinforcement bar has been inserted into an opening <NUM>, a plug <NUM> as shown in <FIG> is inserted into the opening <NUM> to retain the reinforcement bar therein. The opening <NUM> may be sized to receive a <NUM>,<NUM> (<NUM>/<NUM> inch) or <NUM>,<NUM> (<NUM>/<NUM> inch) plug <NUM>, for example.

Each pallet support legs <NUM> may be formed with a thermoplastic or polymer material. Similarly, the top deck <NUM> may also be formed with a thermoplastic or polymer material. The plastic used in the half-size plastic pallet <NUM> may be recyclable.

Another aspect is directed to a method for making a pallet <NUM> with removable pallet support legs <NUM> as described above. The method includes forming a top deck <NUM> with a product support surface <NUM> and an opposing underside <NUM>, with the underside <NUM> having a plurality of snaps openings <NUM> therein. The method further includes forming a plurality of pallet support legs <NUM>. Each pallet support leg <NUM> includes a base <NUM> extending across a width of the top deck <NUM>, and a pair of outer base support elements <NUM>. Each outer base support element <NUM> has a lower end integrally formed with an end of the base <NUM> and an exposed upper end. A pair of outwardly facing snaps <NUM> extend from the exposed upper end of each outer base support element <NUM> to contact the underside <NUM> of the top deck <NUM>. A pair of inwardly facing snaps <NUM> extend from the exposed upper end of each outer base support element <NUM> to contact the underside <NUM> of the top deck <NUM>. The method further includes engaging the pair of outwardly and inwardly facing snaps <NUM>, <NUM> with respective snap openings <NUM> in the underside <NUM> of the top deck <NUM> so that the pallet support legs <NUM> are coupled to the top deck <NUM>.

The top deck <NUM> will now be discussed in greater detail in reference to <FIG>. The top deck <NUM> is formed as one piece, and includes four quadrants <NUM>(<NUM>)-<NUM>(<NUM>). Each quadrant may be generally referenced as quadrant <NUM>. The quadrants <NUM> are symmetrical in design with the exception of shrink wrap gripping members <NUM> only in quadrants <NUM>(<NUM>) and <NUM>(<NUM>).

The shrink wrap gripping members <NUM> are used in the application and retention of shrink wrap over a product being carried by the top deck <NUM>. Shrink wrap is commonly used to secure a product to a pallet. This is often an alternative to banding, although both can be applied if desired.

A problem encountered in applying shrink wrap to a pallet is in securing the ends of the shrink wrap. This problem is encountered both at the start and the finish of shrink wrapping since the wrap might not want to adhere to the product or the pallet, or may fail to retain itself against the product of the pallet at the end.

The shrink wrap gripping members <NUM> are positioned along the sides <NUM> of the top deck <NUM>. There is one shrink wrap gripping member <NUM> on each side <NUM>, i.e., quadrants <NUM>(<NUM>) and <NUM>(<NUM>). In other embodiments, quadrants <NUM>(<NUM>) and <NUM>(<NUM>) may also include a shrink wrap gripping member <NUM> so that all of the quadrants <NUM> are symmetrical in design.

Each shrink wrap gripping member <NUM> takes the form of a two-sided groove, similar to the shape of an anvil. The two-sided groove has a front recess and a rear recess and a narrowed opening there between. The narrowed opening allows the shrink wrap to be located into the groove, but makes it harder for it to come out again. The wrap can be pulled into either the front or rear recesses and can secure an end of the wrap either at the start or at the end of the wrapping process.

Another feature of the top deck <NUM> is to include grooves <NUM> for use as a banding strap locator. A pair of grooves <NUM> is located on each of the longer sides <NUM> of the top deck <NUM>.

Each quadrant <NUM> includes a hand access hole <NUM>. The hand access hole <NUM> provides an easy means for an operator to handle the half-size plastic pallet <NUM>. The hand access hole <NUM> is sized large enough for a user to insert all four fingers therethrough. By providing a hand access hole <NUM> in each quadrant <NUM>, the half-size plastic pallet <NUM> can very easily be grasped by the user for carrying it or for unloading it from a stack of pallets.

The top deck <NUM> includes a number of different product display attachment points for securing a product display or box to the half-size plastic pallet <NUM>. When the half-size plastic pallet <NUM> is on the floor within a store with products thereon, for example, a product display helps to promote the products. <CIT> discloses a fractional plastic pallet with product display attachment points. The '<NUM> patent is assigned to the current assignee of the present invention.

Product display attachment points include display attachment slots <NUM>, <NUM> and <NUM> in the product support surface <NUM> as illustrated in <FIG>. Each display attachment slot <NUM>, <NUM> and <NUM> is rectangular shaped and is sized to receive a tab descending from the base of a product display so as to allow the product display to be held in place on the half-size plastic pallet <NUM>.

A pair of display attachment slots <NUM> is located adjacent each side <NUM>, <NUM> of the top deck <NUM>, for a total of eight display attachment slots <NUM>. There are also eight display attachment slots <NUM> and eight display attachment slots <NUM> in the product support surface <NUM>. Each display attachment slot <NUM> is aligned with a respective display attachment slot <NUM>, and each display attachment slot <NUM> is recessed from a side <NUM>, <NUM> of the top deck <NUM> and also aligned with a respective display attachment slot <NUM>.

Still referring to <FIG>, each display attachment slot <NUM> includes an outer slot <NUM> within the top deck <NUM> and an inner slot <NUM> recessed within the outer slot. The outer slot <NUM> includes sides <NUM> and a partially closed bottom <NUM> forming a curved shelf. The inner slot <NUM> is adjacent the curved shelf <NUM> and is recessed below the outer slot <NUM>. The inner slot <NUM> has a pair of spaced apart sidewalls <NUM> and <NUM>, and a closed bottom <NUM>.

Within the inner slot <NUM>, sidewall <NUM> includes a projection <NUM> extending therefrom, and the opposing sidewall <NUM> includes a tapered member <NUM> extending therefrom. The tapered member <NUM> has a downwards taper towards the projection <NUM>. If the product display tab has an appropriately positioned hole, that hole can engage and lock onto the projection <NUM> or the tapered member <NUM>.

The sidewall <NUM> with the tapered member <NUM> is curved corresponding to the curved shelf <NUM>, whereas the sidewall <NUM> with the projection <NUM> is not curved. The tapered member <NUM> includes a lowermost surface <NUM> that is perpendicular to the closed bottom <NUM> of the inner slot <NUM>. There is a gap between the flat underside <NUM> and the closed bottom <NUM>. The projection <NUM> has a quarter-spherical shape, for example. The tapered member <NUM> is aligned with a center of the projection <NUM>.

Each display attachment slot <NUM> is recessed from a side <NUM>, <NUM> of the top deck <NUM>. A significant portion of the corresponding sides <NUM>, <NUM> of the top deck <NUM> is removed so as to expose the display attachment slot <NUM>. Removal of the corresponding sides <NUM>, <NUM> for the display attachment slots <NUM> is uniform so as to form a pair of spaced apart retention tabs <NUM> for securing a product display tab. The retention tabs <NUM> are at an upper portion of the display attachment slot <NUM>, while the lower portion of the display attachment slot <NUM> is fully exposed.

The top deck <NUM> also includes openings <NUM>, <NUM> for receiving reinforcement bars, as illustrated in <FIG>. The reinforcement bars add strength and durability to the top deck <NUM>. The reinforcement bars may be, but are not limited to, steel or metal, for example. Sides <NUM> have three openings <NUM> and sides <NUM> have two openings <NUM> for receiving the reinforcement bars. After a reinforcement bar has been inserted into an opening <NUM>, <NUM>, a plug <NUM> as shown in <FIG> is inserted into the opening <NUM>, <NUM> to retain the reinforcement bar. The openings <NUM>, <NUM> may be sized to receive a <NUM>,<NUM> (<NUM>/<NUM> inch) or <NUM>,<NUM> (<NUM>/<NUM> inch) plug <NUM>, for example.

As noted above, the half-size plastic pallet <NUM> is repairable. The pallet support legs <NUM> are formed separate from the top deck <NUM>, with the top deck <NUM> being detachable from the pallet support legs <NUM> for pallet repair. Each support leg <NUM> includes snaps <NUM>, <NUM> associated with the outer base support elements <NUM> and snaps <NUM> associated with center base support element <NUM>. The respective snaps <NUM>, <NUM> and <NUM> secure each pallet support leg <NUM> to the underside <NUM> of the top deck <NUM>.

The snaps <NUM> associated with the center base support element <NUM> are secured to corresponding snap openings <NUM> exposed from the underside <NUM> of the top deck <NUM>. Similarly, snaps <NUM>, <NUM> associated with the outer base support elements <NUM> are secured to corresponding snap openings <NUM> exposed from the underside <NUM> of the top deck <NUM>. The outer facing snap pins <NUM> are visible from the sides <NUM> of the top deck <NUM>.

The product support surface <NUM> of the top deck <NUM> includes openings for receiving a jig used to remove a pallet support leg <NUM>. The jig allows contact to be made with all of the snaps <NUM>, <NUM>, <NUM> on a pallet support leg <NUM> so as to un-snap them from the underside <NUM> of the top deck <NUM>.

Referring now to <FIG>, the four nearly symmetrical quadrants <NUM> will be discussed in greater detail. Each quadrant <NUM> includes a pair of spherical carvings <NUM>, <NUM>. The spherical carvings <NUM>, <NUM> may also be referred to as deck scoop areas. The spherical carvings <NUM>, <NUM> respectively reduce the thickness of the top deck <NUM> within each quadrant <NUM>. The spherical carvings <NUM>, <NUM> advantageously reduce the influence of center quadrant deflection on a fork tine's ability to pass through the opening below the top deck <NUM>. Center quadrant deflection may occur at times when the load on the half-size plastic pallet <NUM> is heavy.

In other embodiments, each quadrant <NUM> may include a single spherical carving, such as spherical carving <NUM> or <NUM>. In yet other embodiments, the single spherical carving may partially overlap between spherical carving <NUM> or <NUM>.

Spherical carving <NUM> may be referred to as a first deck scoop area, and spherical carving <NUM> may be referred to as a second deck scoop area. The second deck scoop area <NUM> is larger in size than the first deck scoop area <NUM>. The first deck scoop area <NUM> has a rectangular shape, and the second deck scoop area <NUM> has a square shape.

The underside <NUM> of the top deck <NUM> is made up of ribs that are exposed. The first deck scoop area <NUM> includes a respective hand access hole <NUM>. The hand access hole <NUM> is centered within the first deck scoop area <NUM>. The hand access hole <NUM> is at a peak of the curvature within the first deck scoop area <NUM>. This peak corresponds to the minimum thickness point of the top deck <NUM> within the first deck scoop area <NUM>.

The hand access hole <NUM> includes a wall <NUM> that extends from the product support surface <NUM> to the opposing underside <NUM> of the top deck <NUM>. Exposed ribs <NUM> extend in a first direction, and exposed ribs <NUM> extend in a second direction orthogonal to the first direction within the first deck scoop area <NUM>.

The first deck scoop area <NUM> in each quadrant <NUM> is adjacent an outer side <NUM> of the top deck <NUM>. An outer perimeter area <NUM> of the quadrant <NUM> between the outer side <NUM> and the first deck scoop area <NUM> has a uniform thickness, and is not part of the first deck scoop area <NUM>. The outer perimeter area <NUM> of the quadrant <NUM> extends around a perimeter of the top deck <NUM> for all four quadrants. The perimeter area is adjacent outer sides <NUM> and <NUM>.

The second deck scoop area <NUM> is separated from the first spherical carving <NUM> by a transition wall <NUM>. A thickness of the top deck <NUM> is not reduced at the transition wall <NUM>. The ribs within the second deck scoop area <NUM> include ribs <NUM> extending in a first direction and ribs <NUM> extending in a second direction orthogonal to the first direction.

The second deck scoop area <NUM> includes a plurality of spaced apart openings <NUM> in each quadrant <NUM>, as illustrated in <FIG>. The openings <NUM> extend to the underside <NUM> of the top deck <NUM>. The openings <NUM> may be divided into spaced apart opening sections that are laid out in a grid pattern. Each opening section has a pattern of openings <NUM> that is symmetrical to each of the other opening sections within each second deck scoop area <NUM>.

Another aspect is directed to a method for making a pallet <NUM> with deck scoop areas <NUM>, <NUM> as described above. The method includes forming a top deck <NUM> that is divided into quadrants <NUM>, and forming a plurality of pallet support legs <NUM>. The pallet support legs <NUM> are coupled to an underside <NUM> of the top deck <NUM> and forming an opening below the top deck <NUM> for receiving a lifting member. The top deck <NUM> is formed to include at least one deck scoop area <NUM>, <NUM> on an underside <NUM> thereof in each quadrant <NUM>. A thickness of the top deck <NUM> is reduced in each deck scoop area <NUM>, <NUM> to reduce influence of top deck deflection on ability of the lifting member to pass through the opening between below top deck <NUM>.

The top deck <NUM> may be further configured with provisions to enable attachment of an electronic tracking device. A compartment, for example, may be formed or attached to an underside <NUM> of the top deck <NUM> to carry the electronic tracking device. Fasteners may be used for the attachment, including screws or other hardware, plastic clips, or a combination thereof. The electronic tracking device may be configured to store data during pallet use. The electronic tracking device may include, but is not limited to, communication protocols such as Bluetooth, Bluetooth Low Energy (BLE), RFID, cellular, and GPS.

Referring now to <FIG>, the use of grommets <NUM> within the top deck <NUM> will be discussed. The grommets <NUM> advantageously provide a better grip when items are placed on the product support surface <NUM> of the top deck <NUM>, and provide a better grip with forklift tines on an underside <NUM> of the top deck <NUM>. The grommets <NUM> also advantageously help to hold an identical half-size plastic pallet <NUM> in place when stacked on another half-size plastic pallet <NUM>. Suitable materials for the grommets <NUM> include natural rubber and synthetic rubber, for example.

Each quadrant <NUM> has a pair of grommets <NUM>. One of the grommets <NUM> is in the outer perimeter area <NUM> of the top deck <NUM>. The other grommet <NUM> is within the second deck scoop area <NUM> and is orthogonal to the grommet <NUM> in the outer perimeter area <NUM>. In the illustrated embodiment, there are eight grommets <NUM>. The number, location and size of the grommets <NUM> may vary as readily appreciated by those skilled in the art.

Each grommet <NUM> is inserted into a rectangular shaped grommet opening <NUM> that extends through the top deck <NUM>, as illustrated in <FIG>. The grommet opening <NUM> is stepped down from the upper surface <NUM> of the top deck <NUM> to form a recessed shelf <NUM>. The grommet opening <NUM> has a first perimeter size above the recessed shelf <NUM>.

Below the recessed shelf the opening <NUM> has a second perimeter size that is less than the first perimeter size. Included within the second perimeter size is a divider <NUM>. An upper surface of the divider <NUM> is recessed from the recessed shelf <NUM>, and a lower surface of the divider <NUM> continues to the underside <NUM> of the top deck <NUM>. The divider <NUM> requires that a lower portion of each grommet <NUM> have a slit or gap <NUM> so as to accommodate the divider <NUM>.

Each grommet <NUM> includes an upper section <NUM> that includes an upper lip <NUM> for engaging or resting on the recessed shelf <NUM>. An upper surface <NUM> of each grommet <NUM> is flat and elevated above the product support surface <NUM> of the top deck <NUM>. The transition <NUM> between the upper surface <NUM> and the upper lip <NUM> of each corresponding grommet <NUM> is curved.

A pair of mid-sections <NUM> extend from the upper section <NUM> of each grommet <NUM>. The mid-sections <NUM> are on adjacent sides of the divider <NUM>. A respective lower section <NUM> extends from each mid-section <NUM>. The lower section <NUM> extends through to the underside <NUM> of the top deck <NUM> and is flared for engaging the underside <NUM> of the top deck <NUM>, as illustrated in <FIG>. Each lower section <NUM> includes a lower lip <NUM> that is to engage or rest on the underside <NUM> of the top deck <NUM>.

In addition to the grommets <NUM>, the product support surface <NUM> of the top deck <NUM> includes an array of frictional points <NUM> to prevent slippage of products on the product support surface <NUM>, as illustrated in <FIG>. Each frictional point <NUM> has a circular shape and is in the form of a raised stub, for example. To reduce the weight and amount of material needed to form a half-size plastic pallet <NUM>, the top deck <NUM> and the pallet support legs <NUM> include a number of spaced apart openings <NUM> as discussed above.

Another aspect is directed to a method for making a pallet <NUM> with grommets <NUM> as described above. The method comprises forming a top deck <NUM> having a plurality of grommet openings <NUM> extending therethrough, with each grommet opening <NUM> including a recessed shelf <NUM>. A plurality of grommets <NUM> is inserted into the plurality of grommet openings <NUM>. Each grommet <NUM> comprises an upper section <NUM> comprising an upper lip <NUM> resting on the recessed shelf <NUM>, and an outer exposed surface <NUM> of the upper section <NUM> extending in height above the top deck <NUM>. At least one mid-section <NUM> is adjacent the upper lip <NUM> and extends from the upper section <NUM> to an underside <NUM> of the top deck <NUM>. At least one lower section <NUM> extends from the at least one mid-section <NUM>, and comprises a pair of spaced apart lower lips <NUM> resting on the underside <NUM> of the top deck <NUM>. An outer exposed surface <NUM> of the at least one lower section <NUM> extends in height below the underside <NUM> of the top deck <NUM>. The method further comprises forming a plurality of pallet support legs <NUM>, and coupling the plurality of pallet support legs <NUM> to an underside <NUM> of the top deck <NUM> and forming an opening below the top deck <NUM> for receiving a lifting member.

Referring now to <FIG> and <FIG>, the half-size plastic pallet <NUM> is stackable with other identical half-size plastic pallets <NUM>. The grommets <NUM> adjacent the outer sides <NUM> of the top deck <NUM> help to hold a stacked half-size plastic pallet <NUM> in place. This is accomplished with the upper surface <NUM> of the grommets <NUM> being elevated above the upper product support surface <NUM> of the top deck <NUM>. The elevated upper surface <NUM> of the grommets <NUM> above the product support surface <NUM> of the top deck <NUM> may be within a range of <NUM>,<NUM> to <NUM>,<NUM> (<NUM> to <NUM> inches), for example. This range is not to be limiting since the actual elevated upper surface <NUM> may vary outside of this range.

A pair of corresponding openings <NUM> is in an underside of the pallet support legs <NUM> for engaging with the upper surface <NUM> of the grommets <NUM> of the stacked pallet <NUM>, as illustrated in <FIG> by a cross-sectional view of the stacked half-size plastic pallets <NUM>. Each opening <NUM> is sized to receive the upper section <NUM> of a grommet <NUM>, which includes the upper surface <NUM> as well as a portion of the transition <NUM> between the upper surface <NUM> and the upper lip <NUM>.

In particular, the pallet <NUM> comprises a top deck <NUM> including a product support surface <NUM> and an opposing underside <NUM>. The product support surface <NUM> has a plurality of grommet openings <NUM> extending therethrough, with each grommet opening <NUM> including a recessed shelf <NUM>.

A plurality of grommets <NUM> is inserted into the plurality of grommet openings <NUM>. Each grommet <NUM> comprises an upper section <NUM> comprising an upper lip <NUM> resting on the recessed shelf <NUM>, and an outer exposed surface <NUM> of the upper section <NUM> extends in height above the top deck <NUM>.

A plurality of pallet support legs <NUM> are on the underside <NUM> of the top deck and is aligned with the plurality of grommets <NUM> adjacent the outer sides <NUM> of the top deck <NUM>. Each pallet support leg <NUM> includes a base <NUM> extending across a width of the top deck <NUM>, and a pair of outer base support elements <NUM>. Each outer base support element <NUM> has a lower end integrally formed with an end of the base <NUM>, and an upper end coupled to the underside <NUM> of the top deck <NUM>. An underside of the base <NUM> is configured to engage the upper sections <NUM> of a pair of grommets <NUM> of an identical pallet <NUM> when stacked thereon.

The underside <NUM> of the base <NUM> includes a plurality of grommet openings <NUM>, as illustrated in <FIG>. Each grommet opening <NUM> is configured to receive the upper section <NUM> of a respective grommet <NUM> of the identical pallet <NUM> when stacked thereon. There are four grommet openings <NUM> in the base <NUM> so that the outer pallet support legs <NUM> can be coupled to the top deck <NUM> without being limited to placement adjacent a particular outer side <NUM> of the top deck <NUM>.

The upper section <NUM> of each grommet <NUM> includes an upper surface <NUM>, with a transition <NUM> between the upper surface <NUM> and the upper lip <NUM> being curved. The curved transition <NUM> acts as a guide for positioning the upper surface <NUM> of the upper section <NUM> of the grommet <NUM> into a corresponding opening <NUM> in the base <NUM> of the pallet support legs <NUM>. The plurality of grommet openings <NUM> are positioned at opposing outer sides <NUM> of the top deck <NUM>, with each opposing outer side <NUM> having a pair of spaced apart grommet openings <NUM>.

Another aspect is directed to making a pallet <NUM> that is stackable with other identical pallets <NUM> as described above. The method comprises forming a top deck <NUM> including a product support surface <NUM> and an opposing underside <NUM>. The product support surface <NUM> has a plurality of grommet openings <NUM> extending therethrough, with each grommet opening <NUM> including a recessed shelf <NUM>.

The method further includes inserting a plurality of grommets <NUM> into the plurality of grommet openings <NUM>. Each grommet <NUM> comprises an upper section <NUM> comprising an upper lip <NUM> resting on the recessed shelf <NUM>. An outer exposed surface <NUM> of the upper section <NUM> extends in height above the top deck <NUM>.

The method further includes forming a plurality of pallet support legs <NUM>. Each pallet support leg <NUM> includes a base <NUM> extending across a width of the top deck <NUM>, and a pair of outer base support elements <NUM>. Each outer base support element <NUM> has a lower end integrally formed with an end of the base <NUM>, and an upper end coupled to the underside <NUM> of the top deck <NUM>. An underside of the base <NUM> is configured to engage the upper sections <NUM> of a pair of grommets <NUM> of an identical pallet <NUM> when stacked thereon. The plurality of support legs <NUM> is coupled to the underside <NUM> of the top deck <NUM>, with the plurality of support legs <NUM> being aligned with the plurality of grommets <NUM>.

Another feature of the top deck <NUM> is that it is reconfigurable as a pallet/dolly platform <NUM>. A dolly <NUM> is formed with the addition of dolly wheels <NUM> to the reconfigurable pallet/dolly platform <NUM>, as illustrated in <FIG>. The reconfigurable pallet/dolly platform <NUM> is advantageously reconfigured to support a half-size plastic pallet <NUM> or a half-size dolly <NUM>.

When the reconfigurable pallet/dolly platform <NUM> is configured as a dolly <NUM>, the pallet support legs <NUM> are not coupled to the underside <NUM> of the platform <NUM>. Likewise, when the reconfigurable pallet/dolly platform <NUM> is configured as a pallet <NUM>, the dolly wheels <NUM> are not coupled to the underside <NUM> of the platform <NUM>.

Referring back to <FIG> illustrating the underside <NUM> of the top deck <NUM>, a plurality of dolly wheel attachment areas <NUM> is provided for receiving a plurality of dolly wheels <NUM> when configured as a dolly <NUM>. There are six dolly wheels <NUM> coupled to the underside <NUM> of the top deck <NUM>, with three on each side <NUM>. Each dolly wheel attachment area <NUM> includes four attachment points <NUM> for securing a dolly wheel <NUM>. An additional attachment point may be provided to receive a cover when the top deck <NUM> is being used as a pallet.

In the product support surface <NUM> of the reconfigurable pallet/dolly platform <NUM>, a plurality of dolly wheel wells <NUM> is provided. The plurality of dolly wheel wells <NUM> is aligned with the plurality of dolly wheel receiving areas <NUM>. Each dolly wheel well <NUM> is configured to engage a respective dolly wheel <NUM> from an identical dolly <NUM> stacked thereon. By having the dolly wheel wells <NUM> receiving the dolly wheels <NUM> from a stacked dolly <NUM>, stability is provided as the stacked dollies <NUM> are moved.

In addition, each dolly wheel well <NUM> may include a drainage opening so that water or other liquids do not accumulate. The dolly wheels <NUM> at one end of the dolly <NUM> can swivel about an axis perpendicular to the top deck <NUM>, whereas the other four dolly wheels <NUM> do not swivel.

In particular, the reconfigurable pallet/dolly platform <NUM> comprises a top deck <NUM> including a product support surface <NUM> and an opposing underside <NUM>. The product support surface <NUM> has a plurality of grommet openings <NUM> extending therethrough, with each grommet opening <NUM> including a recessed shelf <NUM>.

The underside <NUM> includes a plurality of pallet support leg attachment areas <NUM>, <NUM> aligned with the plurality of grommet openings <NUM>, and for receiving a plurality of pallet support legs <NUM> when configured as a pallet <NUM>. A plurality of dolly wheel attachment areas <NUM> is for receiving a plurality of dolly wheels <NUM> when configured as a dolly <NUM>.

The product support surface <NUM> includes a plurality of grommets <NUM> inserted into the plurality of grommet openings <NUM>. Each grommet <NUM> comprises an upper section <NUM> comprising an upper lip <NUM> resting on the recessed shelf <NUM>. An outer exposed surface <NUM> of the upper section <NUM> extends in height above the top deck, and is configured to engage an underside <NUM> of the pallet support legs <NUM> from an identical platform <NUM> stacked thereon when configured as a pallet <NUM>.

A plurality of dolly wheel receiving areas <NUM> is aligned with the plurality of dolly wheel wells <NUM>, and is configured to engage the plurality of dolly wheels <NUM> from an identical platform <NUM> stacked thereon when configured as a dolly <NUM>.

The underside of each pallet support leg <NUM> includes a plurality of grommet openings <NUM>, with each grommet opening <NUM> configured to receive the upper section <NUM> of a respective grommet <NUM> of the identical pallet <NUM> when stacked thereon.

Another aspect is directed to making a reconfigurable pallet/dolly platform <NUM> comprising forming a top deck <NUM> including a product support surface <NUM> and an opposing underside <NUM>. The product support surface <NUM> has a plurality of grommet openings <NUM> extending therethrough, with each grommet opening <NUM> including a recessed shelf <NUM>.

The underside <NUM> includes a plurality of pallet support leg attachment areas <NUM>, <NUM> aligned with the plurality of grommet openings <NUM>, and is for receiving a plurality of pallet support legs <NUM> when configured as a pallet <NUM>. A plurality of dolly wheel attachment areas <NUM> is for receiving a plurality of dolly wheels <NUM> when configured as a dolly <NUM>.

Claim 1:
A reconfigurable pallet/dolly platform comprising:
a top deck (<NUM>) including a product support surface (<NUM>) and an opposing underside (<NUM>), and with the product support surface having a plurality of grommet openings (<NUM>) extending therethrough, with each grommet opening including a recessed shelf (<NUM>);
with the underside including:
a plurality of pallet support leg attachment areas (<NUM>, <NUM>) aligned with the plurality of grommet openings and for receiving a plurality of pallet support legs (<NUM>) when configured as a pallet, and
a plurality of dolly wheel attachment areas (<NUM>) for receiving a plurality of dolly wheels when configured as a dolly; and
with the product support surface including:
a plurality of grommets (<NUM>) inserted into the plurality of grommet openings, each grommet comprising
an upper section (<NUM>) comprising an upper lip (<NUM>) resting on the recessed shelf, and an outer exposed surface (<NUM>) of said upper section extending in height above said top deck and configured to engage an underside of the pallet support legs from an identical platform stacked thereon when configured as a pallet,
at least one mid-section (<NUM>) adjacent the upper lip and extending from said upper section to the underside of said top deck, and
at least one lower section (<NUM>) extending from said at least one mid-section, and comprising a pair of spaced apart lower lips (<NUM>) resting on the underside of said top deck, with an outer exposed surface (<NUM>) of said at least one lower section extending in height below the underside of said top deck, and
a plurality of dolly wheel receiving areas (<NUM>) aligned with the plurality of dolly wheel attachment areas and configured to engage the plurality of dolly wheels from an identical platform stacked thereon when configured as a dolly.