PALLET

• US 20090183655A1
• Filed: 01/18/2008
• Published: 07/23/2009
• Est. Priority Date: 01/18/2008
• Status: Active Grant

• Current Assignee: Rehrig Pacific Company
• Original Assignee: Rehrig Pacific Company
• Inventors: Ogburn, Sean T.
• Granted Patent: US 9,988,180 B2
• Time in Patent Office: Days
• US Class Current: 108/57.250
• CPC Class Codes: B65D 19/0016 and each contact surface having a stringer-like shape
• CPC Class Codes: B65D 2519/00034 Plastic
• CPC Class Codes: B65D 2519/00069 Plastic
• CPC Class Codes: B65D 2519/00273 made of more than one piece
• CPC Class Codes: B65D 2519/00288 made of one piece
• CPC Class Codes: B65D 2519/00333 contact surface having a stringer-like shape
• CPC Class Codes: B65D 2519/00407 on the load supporting surface
• CPC Class Codes: B65D 2519/00562 chemical connection, e.g. glued, welded, sealed

Abstract

A pallet has an upper deck portion having an upper planar portion and a lower deck portion having a lower planar portion. Ribs extend from one of the planar portions and are vibration welded to the other planar portion. A peripheral lip extends downwardly from the upper deck portion around the periphery of the lower portion. In this manner, the entire upper deck portion, which includes the entire upper surface of the pallet, is vibration welded to the lower deck portion. Further, the peripheral lip of the upper deck portion hides any flash that might be generated by the vibration welding process.

Claims

1. ) A pallet comprising:

an upper deck portion having a upper planar portion, a peripheral lip protruding downwardly from a periphery of the upper planar portion;

a lower deck portion having a lower planar portion, the lower deck portion including a peripheral wall extending at least substantially about the periphery of the lower deck portion;

a plurality of intersecting ribs integrally molded with one of the upper planar portion and the lower planar portion and vibration welded the other of the upper planar portion and the lower planar portion, with the peripheral wall of the lower deck portion received within the peripheral lip of the upper deck portion.

2. ) The pallet of claim 1 wherein the plurality of intersecting ribs are integrally molded with the lower deck portion.

3. ) The pallet of claim 1 wherein the other of the upper deck portion and the lower deck portion includes a plurality of reinforcing ribs extending therefrom, the plurality of reinforcing ribs received between the plurality of intersecting ribs.

4. ) The pallet of claim 3 wherein the reinforcing ribs do not contact the intersecting ribs.

5. ) The pallet of claim 1 wherein the intersecting ribs include mating portions that protrude relative to the remainder of the intersecting ribs, the mating portions vibration welded to the one of the upper planar portion and the lower planar portion.

6. ) The pallet of claim 1 wherein at least a portion of the peripheral wall includes a recess at an upper exterior surface thereof, the peripheral lip extending downwardly over the recess.

7. ) The pallet of claim 6 wherein the lower deck portion further includes integrally molded columns extending downward.

8. ) The pallet of claim 7 wherein the lower deck portion further includes integrally molded runners extending between lower ends of the columns.

9. ) A lower pallet portion comprising:

a lower planar portion;

a plurality of transversely intersecting ribs extending upwardly from the lower planar portion;

a peripheral wall extending upwardly from a periphery of the lower planar portion and having a recess at an upper exterior surface thereof; and

a plurality of mating portions protruding upwardly from the plurality of ribs and from the peripheral wall.

10. ) The lower pallet portion of claim 9 further including integrally molded columns extending downward.

11. ) The lower pallet portion of claim 10 further including integrally molded runners extending between lower ends of the columns.

12. ) A method for manufacturing a pallet including the steps of:

a) forming a lower pallet portion having a lower planar portion, a peripheral wall of the lower pallet portion having a recess at an upper exterior surface thereof;

b) forming an upper deck portion having a upper planar portion, a peripheral lip protruding downwardly from a periphery of the upper planar portion, one of the upper planar portion and the lower planar portion including a plurality of transversely intersecting ribs and a plurality of mating portions protruding from the plurality of intersecting ribs;

c) placing the upper deck portion on the lower deck portion, with the peripheral wall of the lower deck portion within the peripheral lip of the upper deck portion; and

d) vibration welding the mating portions of the ribs to the other of the upper planar portion and the lower planar portion.

13. ) The method of claim 12 wherein the plurality of intersecting ribs are integrally molded with the lower deck portion.

14. ) The method of claim 12 wherein the lower deck portion further includes integrally molded columns extending downward.

15. ) The method of claim 14 wherein the lower deck portion further includes integrally molded runners extending between lower ends of the columns.

16. ) The method of claim 12 wherein said steps a) and b) are performed by injection molding.

17. ) The method of claim 12 wherein the upper deck portion further includes reinforcing ribs extending downwardly therefrom, the method further including the step of placing the reinforcing ribs between adjacent pairs of the plurality of ribs of the lower deck section.