Blow molded pallet with pre-formed inserts

• US 6,962,115 B2
• Filed: 06/11/2003
• Issued: 11/08/2005
• Est. Priority Date: 02/17/2003
• Status: Expired due to Fees

• Current Assignee: Poly-Flex Incorporated
• Original Assignee: Poly-Flex Incorporated
• Inventors: Wiser, Randal P., Seibel, Amy R., Markling, Floyd F.
• Primary Examiner(s): Chen, Jose V.
• Application Number:
  US10/459,410
• Publication Number:
  US 20040159267A1
• Time in Patent Office: 881 Days
• Field of Search: 108/57.25, 108/57.26, 108/57.27, 108/57.28, 108/51.11, 108/56.1, 108/901, 108/902
• US Class Current: 108/57.25
• CPC Class Codes: B29C 2049/2017 outside the article
• CPC Class Codes: B29C 2049/206 being constructed in such a way that the joining between the insert and the preform or parison is avoided
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 49/20 of articles having inserts or reinforcements ; Handling of inserts or reinforcements
• CPC Class Codes: B29L 2031/7178 Pallets
• CPC Class Codes: B65D 19/0012 forming a continuous plane contact surface
• CPC Class Codes: B65D 19/0026 and each contact surface having a stringer-like shape
• CPC Class Codes: B65D 19/0028 and each contact surface having a discrete foot-like shape
• CPC Class Codes: B65D 19/0036 forming discontinuous or non-planar contact surfaces
• CPC Class Codes: B65D 2519/00034 Plastic
• CPC Class Codes: B65D 2519/00069 Plastic
• CPC Class Codes: B65D 2519/00104 Plastic
• CPC Class Codes: B65D 2519/00129 Metal
• CPC Class Codes: B65D 2519/00134 Wood
• CPC Class Codes: B65D 2519/00139 Plastic
• CPC Class Codes: B65D 2519/00208 Plastic
• CPC Class Codes: B65D 2519/00273 made of more than one piece
• CPC Class Codes: B65D 2519/00278 the load supporting surface and the base surface being identical
• CPC Class Codes: B65D 2519/00288 made of one piece
• CPC Class Codes: B65D 2519/00293 made of more than one piece
• CPC Class Codes: B65D 2519/00303 : Cell type, e.g. honeycomb
• CPC Class Codes: B65D 2519/00318 : made of one piece
• CPC Class Codes: B65D 2519/00323 : made of more than one piece
• CPC Class Codes: B65D 2519/00333 : contact surface having a stringer-like shape
• CPC Class Codes: B65D 2519/00338 : contact surface having a discrete foot-like shape
• CPC Class Codes: B65D 2519/00358 : Cell type, e.g. honeycomb
• CPC Class Codes: B65D 2519/00363 : grid type, e.g. perforated plate
• CPC Class Codes: B65D 2519/00373 : whereby at least one spacer is made of one piece
• CPC Class Codes: B65D 2519/00388 : Cell type, e.g. honeycomb
• CPC Class Codes: B65D 2519/00407 : on the load supporting surface
• CPC Class Codes: B65D 2519/00412 : on the base surface
• CPC Class Codes: B65D 2519/00432 : Non-integral, e.g. inserts B65D2519/00462 takes precedence
• CPC Class Codes: B65D 2519/00557 : without separate auxiliary elements
• CPC Class Codes: B65D 2519/00567 : mechanical connection, e.g. snap-fitted
• CPC Class Codes: B65D 2519/00711 : removable lid or covers
• CPC Class Codes: B65D 2519/00835 : Integral
• CPC Class Codes: B65D 2519/0084 : Separated elements, e.g. including in-moulded elements
• CPC Class Codes: B65D 2519/0094 : nestable
• CPC Class Codes: B65D 2519/00985 : the pallet being not usable as a pallet after dismounting

Abstract

A pallet system includes a pallet body. The pallet body is formed from a first, independently formed first portion and a second blow molded second upper portion insert molded to the first portion. The pallet body may have two to eight recesses for forklift truck fork access. The second upper portion has a generally rectangular surface for carrying loads. The portions may have anti-skid properties, for example, a knurled topside surface or rubber coated bottom. At least one foot is attached to the second upper portion by insert molding. At least one runner may be attached to each foot to form part of the first portion. At least one stringer is attached to each runner to add further stability to the pallet. The runners and feet have channels or protruding members to effectively mate with the second upper portion. The system may also have top cap and tie members to affix the cap to one or more pallet bodies as well as high-friction inserts to permit the pallet from sliding on a surface or objects from sliding on the pallet.

Claims

1. A method for forming a pallet, the method comprising the steps of:

a) forming a first component in a first blow molding process having an attachment portion exhibiting a non-planar surface;

b) positioning the first component in a mold for a second component;

c) placing at least one insert having a relatively hi friction characteristic greater than a material used to form said first and second components within the mold for the second component; and

d) forming the second component to conformally encase and interlock with the attachment portion of the first component and the at least one insert in a second blow molding process with the second component and such that a portion of the at least one insert is raised above a support surface of one of the first and second components.

2. The method of claim 1 wherein the at least one insert is formed of a blend of a hard plastic material and a rubber.

3. The method of claim 2 wherein the blend is at least 50% by weight of the hard plastic material.

4. The method of claim 3 wherein the hard plastic material is polyethylene.

5. The method of claim 1 wherein the first and second components are formed of a hard plastic material.

6. The method of claim 1 wherein said support surface is load bearing and wherein a plurality of said inserts are arrayed over said support surface.

7. The method of claim 1 further comprising:

a) at least one first insert positioned on the first component; and

b) at least one second insert positioned on the second component.

8. The method of claim 1 wherein the at least one insert is generally circular in shape.

9. The method pallet of claim 1 further comprising a third component formed in a third blow molding operation and conformally interconnected to the second component at a location spaced from the first component in the second blow molding operation.

10. The method of claim 9 further comprising securing at least one reinforcing member to said pallet.

11. The method of claim 1 wherein the second component exhibits a generally non-planar support surface.

12. The method of claim 11 wherein the second component is molded to exhibit a generally parabolic load bearing support surface and wherein the insert is conformally encased by and exposed above said load bearing surface.

13. The method of claim 1 wherein the first component is formed of a hard plastic material and a rubber.

14. The method of claim 1 wherein the second component is formed of a blend of a hard plastic material and a rubber.

17. The method of claim 1 wherein said attachment portion comprises a protruding rib.

18. The method of claim 1 wherein said attachment portion comprises a ridge.

19. The method of claim 1 wherein said attachment portion comprises a channel.

20. The method of claim 1 wherein said attachment portion comprises a hole.

21. The method of claim 1 wherein said attachment portion comprises a non-planar surface selected from a class including protrusions, ribs, ridges, channels and holes.

15. A method for forming a pallet, the method comprising the steps of:

a) placing at least one insert in a mold for a first component;

b) forming the first component to conformally encase a portion of the at least one insert in a first blow molding process and such that a portion of the at least one insert is raised above a support surface of the first component and further forming the first component to have an attachment portion exhibiting a non-planar surface;

c) positioning the first component in a mold for a second component; and

d) forming the second component to conformally encase and interlock with the attachment portion in a second blow molding process.

16. The method of claim 15 further comprising the step of placing a second insert in the mold for the second component prior to forming the second component.

22. A method for forming a pallet, the method comprising the steps of:

a) forming a first component in a first blow molding operation to have an attachment portion exhibiting a non-planar attachment surface selected from a class including protrusions, ribs, ridges, channels and holes;

b) positioning the first component in a mold for a second component; and

c) forming the second component to conformally encase and interlock with the attachment portion in a second blow molding process.

23. A method as set forth in claim 22 for forming a pallet including the step of placing at least one insert having a friction characteristic greater than a material used to mold said first and second components in a mold for said first component to conformally encase a portion of the at least one insert in said first blow molding operation and such that a portion of the at least one insert is raised above a support surface of the first component.

24. A method as set forth in claim 22 for forming a pallet including the step of placing at least one insert having a friction characteristic greater than a material used to mold said first and second components in a mold for said second component to conformally encase a portion of the at least one insert in said second blow molding operation and such that a portion of the at least one insert is raised above a support surface of the second component.

25. The method of claim 22 further comprising securing at least one reinforcing member to said pallet.