Pallet
First Claim
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1. A method for manufacturing a pallet including the steps of:
- a) forming a lower deck portion having a lower planar portion, a peripheral wall of the lower deck 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, wherein the lower deck portion is integrally molded as a single part, and wherein the upper deck portion is integrally molded as a single part;
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.
1 Assignment
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Accused Products
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.
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Citations
21 Claims
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1. A method for manufacturing a pallet including the steps of:
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a) forming a lower deck portion having a lower planar portion, a peripheral wall of the lower deck 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, wherein the lower deck portion is integrally molded as a single part, and wherein the upper deck portion is integrally molded as a single part; 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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method for manufacturing a pallet including the steps of:
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a) forming a lower deck portion having a lower planar portion and a plurality of columns extending downward from the lower planar portion, the plurality of columns integrally molded with the lower planar portion, a peripheral wall of the lower deck portion extending upward from the lower planar portion about the periphery of the lower planar portion, the peripheral wall 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, wherein the lower deck portion is integrally molded as a single part, and wherein the upper deck portion is integrally molded as a single part; c) placing the upper deck portion on the lower deck portion, with the recess of 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, such that flashing from the vibration welding is received in the recess behind the peripheral lip. - View Dependent Claims (20, 21)
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Specification