Twin-sheet thermoformed pallet with high stiffness deck
First Claim
Patent Images
1. A twin-sheet thermoformed thermoplastic pallet, comprising;
- a) a load-bearing deck formed of a first sheet of thermoplastic material defining a plane and a second sheet of thermoplastic material fused to the first sheet in selected locations; and
b) at least four feet arrayed in a rectangular array, each foot being a downwardly protruding portion of each of said first and second sheets joined together at a terminating foot floor, wherein between each foot of the array and every other of said four feet is defined a deck portion, each said deck portion being reinforced by at least one rib structure extending across said deck portion and between each of said legs, and wherein each rib is defined by at least four pockets arrayed to form the extending rib, the pockets fusing a portion of said second sheet to said first sheet at approximately the plane defined by the first sheet the pockets being elongated in a direction the ribs extend, and wherein at least two of said pockets are joined by an upstanding solid web formed in said second sheet.
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Abstract
The high stiffness of the legs of a twin-sheet thermoformed pallet are effectively made to contribute to the overall stiffness of the pallet deck by utilizing vertical webs which tie into the legs through a plurality of special purpose depressions or knee Joints and which work with narrow channels in the bottom deck which extend parallel to the predominate lines of stress expected to be experienced by the pallet.
82 Citations
13 Claims
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1. A twin-sheet thermoformed thermoplastic pallet, comprising;
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a) a load-bearing deck formed of a first sheet of thermoplastic material defining a plane and a second sheet of thermoplastic material fused to the first sheet in selected locations; and b) at least four feet arrayed in a rectangular array, each foot being a downwardly protruding portion of each of said first and second sheets joined together at a terminating foot floor, wherein between each foot of the array and every other of said four feet is defined a deck portion, each said deck portion being reinforced by at least one rib structure extending across said deck portion and between each of said legs, and wherein each rib is defined by at least four pockets arrayed to form the extending rib, the pockets fusing a portion of said second sheet to said first sheet at approximately the plane defined by the first sheet the pockets being elongated in a direction the ribs extend, and wherein at least two of said pockets are joined by an upstanding solid web formed in said second sheet.
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2. A twin-sheet thermoformed thermoplastic pallet, comprising;
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a) a means for forming a deck formed of an upper sheet of thermoplastic material defining a plane and a lower sheet of thermoplastic material; b) at least four support means for supporting the deck means arrayed in a rectangular array, wherein between each support means and every other of said support means is a means for resisting deflection when the means for forming a deck is subjected to a deflection producing load, and wherein each means for resisting deflection includes at least four pockets arrayed to form the means, the pockets fusing a portion of said lower sheet to said upper sheet at approximately the plane defined by the upper sheet, and the pockets being elongated in a direction the means for resisting deflection extend, and wherein at least two of said pockets are joined by an upstanding solid web formed in said lower sheet, wherein the means for resisting deflection are positioned to be generally parallel to the predominant lines of stress experienced in common pallet loading conditions to thereby optimize deck stiffness between the support means.
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3. A twin-sheet thermoformed thermoplastic pallet comprising:
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a) an upper thermoplastic sheet, said upper sheet defining a pallet deck top surface; and b) a lower thermoplastic sheet fused in selected locations to the upper thermoplastic sheet, wherein a plurality of upwardly opening legs are formed in the fused upper sheet and lower sheet, and a deck defined by the upper sheet and the lower sheet extends between said legs, and a plurality of downwardly opening pockets are formed in the lower sheet and fused to the upper sheet, each pocket being longer than it is wide, and fused sidewardly to at least one adjacent pocket, and wherein an upwardly opening joint depression is formed in the upper sheet adjacent to a leg, and wherein one of said pockets in said lower sheet is fused to said joint depression to define a rib extending from a leg. - View Dependent Claims (4, 5)
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6. A twin-sheet thermoformed thermoplastic pallet, comprising;
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a) a load-bearing deck formed of an upper sheet of thermoplastic material defining a plane and a lower sheet of thermoplastic material; b) at least four feet arrayed in a rectangular array, each foot being a downwardly protruding portion of each of said upper and lower sheets joined together at a terminating foot floor; and c) a deck portion defined between each foot of the array and every other of said four feet, wherein said deck portion is reinforced by at least one rib structured extending across said deck portion and between each of said other four feet, wherein each rib structure is defined by at least four aligned pockets, and each pocket is formed by a portion of said lower sheet fused to said upper sheet at approximately the plane defined by the upper sheet the pockets being elongated in a direction the ribs extend, and wherein at least two of said pockets are joined by an upstanding solid web formed in said lower sheet, and wherein the ribs are positioned to generally be parallel to the predominant lines of stress experienced in common pallet loading conditions to thereby optimize deck stiffness between the supporting feet. - View Dependent Claims (7, 8, 9, 10)
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11. A twin-sheet thermoformed thermoplastic pallet comprising:
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a) a deck having an upper skin and a lower skin, the upper skin being fused to the lower skin at selected locations; b) a plurality of feet connected to the deck, wherein each foot is formed from the upper skin and lower skin and has an upwardly opening cavity; c) a plurality of downwardly opening pockets formed in the pallet lower skin, wherein each pocket is longer than it is wide, and wherein at least a first pocket and a second pocket are formed in closely spaced relation to one another such that a web of fused plastic material is defined between the first pocket and the second pocket, and wherein said at least first pocket and second pocket define a reinforcing deck rib; and d) a downwardly extending shell formed in the deck adjacent a foot cavity, and fused to the deck lower skin, wherein portions of said first pocket are fused to said shell, the foot being thereby joined to the rib. - View Dependent Claims (12, 13)
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Specification