Blow molded pallet with inserts

• US 6,976,437 B2
• Filed: 02/17/2003
• Issued: 12/20/2005
• Est. Priority Date: 02/17/2003
• Status: Expired due to Fees

• Current Assignee: Poly-Flex Incorporated
• Original Assignee: Poly-Flex Incorporated
• Inventors: Seibel, Amy R., Fisch, Robert J., Wiser, Randal P., Markling, Floyd F.
• Primary Examiner(s): Chen, Jose V.
• Application Number:
  US10/368,284
• Publication Number:
  US 20040159266A1
• Time in Patent Office: 1,037 Days
• Field of Search: 108/57.25, 108/57.26, 108/57.27, 108/57.28, 108/51.11, 108/56.1
• 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.

Claims

1. A pallet comprising:

a pallet stabilizing component including a plurality of support portions and a plurality of attachment portions; and

a load bearing component having a hollow interior cavity space defined between upper and lower surfaces and wherein an attachment portion of said load bearing component is blow molded to include a plurality of attachment surfaces having shapes that are conformally bonded and interlocked in complementary mating relation with each of said attachment portions and whereby said pallet stabilizing component is integrated into said load bearing component.

2. The pallet of claim 1 further comprising four recesses for four-way access.

3. The pallet of claim 1 wherein the pallet stabilizing component includes a plurality of runners.

4. The pallet as set forth in claim 1 wherein said pallet stabilizing component includes a plurality of feet and wherein each attachment surface is blow molded to conformally bond and interlock with each of said plurality of feet.

5. The pallet as set forth in claim 1 wherein said plurality of support portions comprise a plurality of runners and wherein each runner includes a plurality of feet.

6. The pallet of claim 1 wherein the load bearing component comprises a waffle configuration.

7. The pallet of claim 1 wherein the pallet stabilizing component comprises a honeycomb configuration.

8. The pallet of claim 1 further comprising a recess for receiving forks of a fork lift.

9. The pallet of claim 1 wherein an underside surface of the load bearing component has pocket formed to provide anti-slip properties.

10. The pallet of claim 1 wherein a bottom of the pallet stabilizing component has pockets for varying the weight to strength ratio.

11. The pallet of claim 1 wherein the load bearing component is a first color;

and wherein the pallet stabilizing component is a second color.

12. The pallet of claim 1 wherein the pallet stabilizing component is blow molded.

13. The pallet of claim 1 wherein said pallet stabilizing component is comprised of at least one of the following materials:

wood, metal or plastic.

14. A method of blow molding a pallet comprising the steps of

a) forming a pallet stabilizing component having a support portion and an attachment portion;

b) inserting the pallet stabilizing component into a mold and exposing said attachment portion in a mold cavity; and

c) blow molding a load bearing component having a hollow interior cavity space to conformally bond in interlocking, complementary relation with said attachment portion, whereby said pallet stabilizing portion and load bearing portion are integrated to one another to form a pallet.

15. The method of claim 14 wherein said pallet stabilizing component comprises first and second runners, wherein said first and second runners each include a plurality of feet, and wherein said first and second runners further include a protruding attachment member.

16. The method of claim 15 wherein at least one protruding member comprises a flange.

17. The method of claim 14 wherein said attachment portion comprises a cavity.

18. A method of forming a plastic pallet comprising the steps of:

a) forming first and second plastic runners, wherein each of said first and second runners has a support portion and an attachment portion;

b) inserting the first and second runners into a mold and exposing each attachment portion in a mold cavity;

c) blow molding a load bearing component having a hollow interior cavity to conformally engage and bond to each attachment portion to integrate said first and second runners to said load bearing component and form a pallet;

d) ejecting the pallet from the mold; and

e) allowing the pallet to cool.

19. The method of claim 18 further comprising, between steps b) and c), the step of holding at least one of said first and second runners in place by a clamp during the blow molding of the load bearing component.

20. The method of claim 18 further comprising the step of inserting a reinforcing member into said mold during the blow molding of the load bearing component, whereby the reinforcing member becomes encased in said pallet.

21. The method of claim 18 further comprising the step of inserting a reinforcing member into said load bearing component as said pallet cools, whereby surfaces of said load bearing component shrink around said reinforcing member.

22. The method of claim 18 wherein said first and second runners each include a plurality of feet and wherein said attachment portion comprises a plurality of attachment surfaces including protrusions and/or recesses at each of said plurality of feet and wherein said load bearing component is molded to interlock in complementary engagement with said attachment surfaces.

23. The method of claim 18 wherein a plurality of feet extend from said first and second runners, wherein each of said plurality of feet includes a protruding member, and wherein each protruding member is conformally interlocked into the load bearing component.

24. The method of claim 23 wherein at least one protruding member comprises a flange.

25. The method of claim 24 wherein at least one flange includes a rib.

26. The method of claim 24 wherein at least one flange includes a groove.

27. A pallet comprising:

a pallet stabilizing component including a plurality of runners and wherein a plurality of feet project from said plurality of runners and further including a plurality attachment members; and

a load bearing component having a hollow interior cavity space defined between upper and lower surfaces and wherein an attachment portion of said load bearing component is blow molded to bond to and define a shape that conformally interlocks in complementary relation with each attachment member and whereby said plurality of runners and feet are integrated into said load bearing component.

28. The pallet of claim 27 further comprising four recesses for four-way access.

29. A pallet comprising:

a pallet stabilizing component comprising a plurality of feet and wherein said plurality of feet each include a protruding member; and

a load bearing component having a hollow interior cavity space defined between upper and lower surfaces and wherein a plurality of attachment surfaces of said load bearing component are blow molded to define a complementary shape that conformally interlocks with and bonds to each protruding member and whereby said plurality of feet are integrated into said load bearing component to form a pallet.

30. The pallet of claim 29 wherein said protruding member comprises a flange.

31. The pallet of claim 30 wherein at least one flange includes a groove and wherein said top load bearing component includes a lip that interlocks with said groove.

32. The pallet of claim 29 wherein said plurality of feet extend from a plurality of runners.

33. The pallet of claim 29 wherein said plurality of feet extend from a plurality of runners, wherein said protruding member comprises a flange, and wherein said load bearing component conformally encases a substantial portion of each flange.

34. A method of blow molding a pallet comprising the steps of

a) forming a pallet stabilizing component having a support portion and an attachment portion;

b) inserting the pallet stabilizing component into a mold and exposing said attachment portion in a mold cavity; and

c) blow molding a load bearing component having a hollow interior cavity space and wherein a portion said load bearing component forms a complementary shape that interlocks with said attachment portion, whereby said pallet stabilizing component and said load bearing component are integrated to one another to form a pallet.

35. The method of claim 34 wherein said attachment portion comprises a protruding member.

36. The method of claim 35 wherein said protruding member includes a groove.

37. The method of claim 34 wherein said attachment portion comprises a flange.

38. A method of blow molding a pallet comprising the steps of

a) forming a pallet stabilizing component having a support portion and an attachment portion including a recess;

b) inserting the pallet stabilizing component into a mold and exposing said attachment portion in a mold cavity; and

c) blow molding a load bearing component having a hollow interior cavity space to conformally bond and interlock in complementary relation with said recess portion, whereby said pallet stabilizing component and load bearing component are integrated to one another to form a pallet.