INTEGRATED TRAY AND PALLET SYSTEM

Abstract

The invention is directed to an integrated plastic tray and pallet system. The system includes a molded plastic pallet having an upper surface with tray components integrally formed with the remainder of the pallet extending upward from the upper surface. A plurality of pallet feet extend downward from a lower surface of the pallet. The pallet also includes side walls extending upward from the periphery of the upper surface. The system may include additional pallet and integrated tray structures without the pallet feet, and a top cap.

Claims

1. An integrated tray and pallet system comprising: a first generally rectangular pallet base having a planar upper surface; and, a plurality of integrally formed trays having tray walls extending upward from the upper surface of the first pallet base.

2. The integrated tray and pallet system of claim 1 further comprising a plurality of feet extending downward from a bottom surface of the first pallet base.

3. The integrated tray and pallet system of claim 2 further comprising: a first side wall extending upward from an edge of a first side of the first pallet base; a second side wall extending upward from an edge of a second side of the first pallet base; a third side wall extending upward from an edge of a third side of the first pallet base; and, a fourth side wall extending upward from an edge of a fourth side of the first pallet base.

4. The integrated tray and pallet system of claim 3 wherein each of the plurality of integrally formed trays is rectangular.

5. The integrated tray and pallet system of claim 4 wherein the plurality of integrally formed trays form an array of columns and rows.

6. The integrated tray and pallet system of claim 5 wherein the array is five by two.

7. The integrated tray and pallet system of claim 3 wherein each of the first, second, third and fourth side walls include a plurality of outwardly extending ribs.

8. The integrated tray and pallet system of claim 1 wherein the first pallet base and the plurality of integrated trays are formed from a molded plastic.

9. The integrated tray and pallet system of claim 1 further comprising: a second generally rectangular pallet base having a planar upper surface; and, a plurality of integrally formed trays having tray walls extending upward from the upper surface of the second pallet base, the second pallet base configured to stack on the first pallet base.

10. The integrated tray and pallet system of claim 9 further comprising a top cap configured to be placed on top of the second pallet base.

11. The integrated tray and pallet system of claim 3 wherein the first side wall, the second side wall, the third side wall and the fourth side wall form portions of the tray wall for respective ones of the plurality of integral trays.

12. An integrated tray and pallet system comprising: a first plastic rectangular pallet base having an upper planar support surface; and, a first tray integrally formed with first pallet base having tray walls extending upward from the support surface.

13. The integrated tray and pallet system of claim 12 further comprising a second tray integrally formed with the first pallet base having tray walls extending upward from the support surface.

14. The integrated tray and pallet system of claim 12 further comprising a plurality of additional trays integrally formed with the first pallet base having tray walls extending upward from the support surface.

15. The integrated tray and pallet system of claim 14 wherein the first tray and the additional plurality of trays form an array of trays on the first pallet base.

16. The integrated tray and pallet system of claim 15 wherein each of the first tray and the additional plurality of trays is rectangular.

17. The integrated tray and pallet system of claim 14 having a plurality of plastic feet extending downward from a bottom surface of the first rectangular plastic pallet base.

18. The integrated tray and pallet system of claim 17 further comprising: a first plastic side wall extending upward from an edge of a first side of the first rectangular plastic pallet base; a second plastic side wall extending upward from an edge of a second side of the first rectangular plastic pallet base; a third plastic side wall extending upward from an edge of a third side of the first rectangular plastic pallet base; and, a fourth plastic side wall extending upward from an edge of a fourth side of the first rectangular plastic pallet base.

19. The integrated tray and pallet system of claim 18 wherein each tray includes a tray wall formed from one of the first plastic side wall, the second plastic side wall, the third plastic side wall and the fourth plastic side wall.

20. The integrated tray and pallet system of claim 19 wherein each tray includes a tray wall having a first end segment, a middle segment and a second end segment wherein a height of the middle segment is less than a height of the first end segment and a height of the second end segment.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0022] FIG. 1 is a perspective view of an integrated tray and pallet system in accordance with the present invention;

[0023] FIG. 2 is a bottom perspective view of the tray and pallet system of FIG. 1;

[0024] FIG. 3 is a bottom perspective view of a tray without pallet feet;

[0025] FIG. 4 is a perspective view of a complete stack of a tray with pallet feet, four trays without pallet feet and a top cap in accordance with an aspect of the present invention;

[0026] FIG. 5 is a perspective view of a plurality of complete stacks of FIG. 4;

[0027] FIG. 6 is a cross-sectional view of a mold for forming a tray with feet and without feet;

[0028] FIG. 7 is a top perspective exploded view of an integrated tray and pallet system having a base pallet with legs and a stacking pallet without legs;

[0029] FIG. 8 is a bottom perspective exploded view of the integrated tray and pallet system having a base pallet with legs and a stacking pallet without legs of FIG. 7;

[0030] FIG. 9 is a side view of an integrated tray and pallet; and,

[0031] FIG. 10 is a perspective view of the integrated tray and pallet of FIG. 9.

DETAILED DESCRIPTION

[0032] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0033] The present invention overcomes many of the issues of having a pallet with a separate tray or plurality of trays by integrating the tray (or trays) directly into the pallet. That is, the trays are integrally formed with the rest of the pallet in the same mold.

[0034] An integrated tray and pallet system 10 is shown in FIGS. 1-2. The system can be viewed as a pallet 12 having integrally formed trays 14 extending upward from an upper surface 16 of the pallet 12. The upper surface 16 has a generally rectangular shape. The pallet 12 also includes a plurality of feet 18 extending downwardly from a lower surface 20 of the pallet 12.

[0035] The pallet 12 has a first side wall 22, a second side wall 24, a third side wall 26 and a fourth side wall 28 extending upward about a perimeter of the upper surface 16. The trays 14 are defined by upwardly extending interior walls 30 combined with a portion of one or more of the pallet side walls 22, 24, 26 and 28, and the upper surface 16.

[0036] While the pallet is shown having three rows of three feet 18 each, it can have more or fewer depending on the size of the pallet desired. Additionally, the pallet 12 can be provided with additional pallet features, such as runners connecting the feet, internal reinforcement, etc. As partially shown in FIG. 1, the side walls 22, 24, 26 and 28 include outwardly extending ribs forming rectangular openings. Similarly, the upper or lower surfaces can include ribs and/or openings.

[0037] The pallet system 10 of FIG. 1 also shows one of the trays 14 loaded with a product 32. Different products can be placed in each of the trays 14.

[0038] In the embodiment of FIG. 1, ten trays 14 are shown in a five by two array. However, more or fewer trays 14 can be formed in various sizes, shapes and positions on the upper surface as desired for a particular purpose.

[0039] The internal walls 30 can be formed to have various features. In the example of FIG. 1, each wall 30 includes a first end portion 34, a second end portion 36 and a middle portion 38. The middle portion 38 has a height that is lower than a height of the first and second portions 34, 36. Collectively, four end portions from four trays 14 form columns in the interior of the pallet 12 as illustrated in FIG. 1.

[0040] The system can also include the combination pallet with integral tray without all of the pallet features. For example, referring to FIG. 3, a pallet 40 is shown without feet. Instead, the pallet 40 includes a smooth lower surface 42. The opposing upper surface can be formed to include the integral trays identical to the pallet 12 and trays 14 of FIG. 1. The pallet 40 includes perimeter lip or skirt 45 that enables the pallet 40 to securely stack onto another pallet 12 with feet, or another pallet 40 without feet.

[0041] A stack 44 of pallets with a top cap 46 (which can also be part of the system) is shown in FIG. 4. The top cap 46 includes structures 48 for accepting the feet 18 of a pallet 12 having feet. Accordingly, multiple such stacks 44 can be placed on top of each other as shown in FIG. 5.

[0042] The entire system is preferably formed from an injection molded plastic. FIG. 6 illustrates an injection mold 50 for forming either the pallet 12 having feet or the pallet 40 without feet but having a perimeter lip for stacking on other pallets. The mold 50 includes a stationary mold half 52 and two moving mold halves. The moving mold halves include a first moving mold half 54 for forming feet 18, and a second moving mold half 46 for forming the lip or skirt 45. Accordingly, the upper features of each pallet 12 and 40 are identical.

[0043] While the system is preferably plastic, other materials (e.g., metal reinforcements) can be used as necessary.

[0044] FIGS. 7-8 show an exploded view of an integrated tray and pallet 60 having feet 18 and an integrated tray and pallet 62 without feet that can be stacked on the pallet 60 with feet. FIGS. 9-10 show views of just the tray and pallet 60. Both pallets 60, 62 are similar to those shown in FIGS. 1-5, however, the middle portion 38 of each wall 30 is less pronounced (i.e., high).

[0045] As also evident in the pallet 10 of FIG. 1, the side walls 22, 24, 26 and 28 of the tray and pallet 60 have an upper portion 64 that is inset from the rest of the side wall. This forms a ledge 66 around the periphery of the side walls that will support the skirt 45 of a pallet 62 without legs that is stacked on top of it. Additionally, the horizontal top wall 68 of the upper portion 64 will contact the edge of the bottom surface 45 of the pallet 62.

[0046] Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.