Pallet

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.

Claims

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.

2. The method of claim 1 wherein the plurality of intersecting ribs are integrally molded with the lower deck portion.

3. The method of claim 1 wherein the lower deck portion further includes columns extending downward from the lower deck portion and integrally molded with the lower deck portion.

4. The method of claim 3 wherein the lower deck portion further includes integrally molded runners extending between lower ends of the columns.

5. The method of claim 1 wherein said steps a) and b) are performed by injection molding.

6. The method of claim 2 wherein the upper deck portion further includes reinforcing ribs extending downwardly therefrom, the method further including the step of placing the reinforcing ribs between adjacent pairs of the plurality of ribs of the lower deck section.

7. The method of claim 1 further including the step of: e) accommodating flashing generated by the vibration welding of step d) in the recess.

8. The method of claim 7 wherein said step e) further includes the step of accommodating the flashing behind the peripheral lip.

9. The method of claim 8 wherein the lower deck portion further includes a plurality of columns extending downward from the lower planar portion, wherein the plurality of columns are integrally molded with the lower planar portion.

10. The method of claim 8 wherein the lower deck portion further includes a plurality of columns extending downward from the lower deck portion, the peripheral wall extending about the plurality of columns.

11. The method of claim 10 wherein the plurality of columns are integrally molded with the lower planar portion.

12. The method of claim 8 wherein the lower deck portion further includes a plurality of columns extending downward from the lower planar portion, the peripheral wall extending about the lower planar portion.

13. The method of claim 12 wherein the plurality of columns are integrally molded with the lower planar portion.

14. The method of claim 12 wherein the recess extends adjacent the plurality of columns.

15. The method of claim 14 wherein the recess extends about the plurality of columns.

16. The method of claim 1 wherein the peripheral wall of the lower deck portion has the recess formed in an exterior surface thereof.

17. The method of claim 1 wherein the plurality of intersecting ribs and the mating portions are integrally molded with the lower planar portion, and wherein the mating portions are melted to the upper planar portion during the vibration welding step.

18. The method of claim 11 wherein the pallet consists of the single part providing the lower deck section and the single part providing the upper deck section.

19. A method for manufacturing a pallet including the steps of: 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.

20. The method of claim 19 wherein the plurality of intersecting ribs and the mating portions are integrally molded with the lower planar portion, and wherein the mating portions are melted to the upper planar portion during the vibration welding step.

21. The method of claim 19 wherein the pallet consists of the single part providing the lower deck section and the single part providing the upper deck section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a pallet according to one embodiment of the present invention.

(2) FIG. 2 is an exploded view of the pallet of FIG. 1.

(3) FIG. 3 is an enlarged exploded view of a quarter of the pallet of FIG. 2.

(4) FIG. 3A is a bottom perspective exploded view of the quarter of the pallet of FIG. 3.

(5) FIG. 4 is a top view of the bottom deck portion of FIG. 2.

(6) FIG. 5 is a perspective view of a quarter of the pallet of FIG. 1.

(7) FIG. 6 is a section view of the pallet taken along lines 6-6 of FIG. 5.

(8) FIG. 7 is a section view through the pallet of FIG. 1 taken along lines 7-7 of FIG. 5.

(9) FIG. 8 is a top view of the pallet of FIG. 1.

(10) FIG. 9 is a front view of the pallet of FIG. 1.

(11) FIG. 10 is a side view of the pallet of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(12) A pallet 10 according to one embodiment of the present invention is shown in FIG. 1. The pallet 10 includes an upper deck portion 12 secured to a lower deck portion 14. The upper deck portion 12 includes an upper planar portion 16, which provides the entire upper surface of the pallet 10. Openings 18 through the upper planar portion 16 reduce weight and provide drainage and ventilation.

(13) The lower deck portion 14 includes a plurality of columns 20 extending downwardly and integrally molded therewith. The lower deck portion 14 further includes runners 22 extending between lower ends of the columns 20.

(14) FIG. 2 is an exploded view of the pallet 10. As shown, the lower deck portion 14 further includes a lower planar portion 28 having a plurality of transversely intersecting ribs 26 extending upwardly therefrom. The lower deck portion 14 further includes a peripheral wall 30 extending around the periphery of the lower deck portion 14.

(15) FIG. 3 is an exploded perspective view of a quarter of the pallet 10 of FIG. 2 (only a quarter is shown, so that more detail is visible, the symmetry of the pallet 10 is evident from FIGS. 1 and 2). FIG. 3A is a bottom perspective view of the quarter of the pallet 10 of FIG. 3. Referring to FIGS. 3 and 3A, the intersecting ribs 26 include a plurality of protruding mating portions 32 protruding therefrom. In particular, the mating portions 32 are formed at the intersections of the ribs 26. The upper exterior surface of the peripheral wall 30 includes a slight recess 34.

(16) The upper deck portion 12 includes integral reinforcing ribs 38 protruding downward from the upper planar portion 16. An integral peripheral lip 40 extends downward from the periphery of the upper planar portion 16.

(17) FIG. 4 is a top view of the bottom deck portion 14. As shown, the ribs 26 intersect the columns 20 and peripheral wall 30 and extend through the columns 20.

(18) FIG. 5 is a perspective view of the quarter of the pallet 10 in an assembled condition. As shown, when assembled, the peripheral lip 40 of the upper deck portion 12 covers at least a substantial portion of the recess 34 in the peripheral wall 30.

(19) FIGS. 6 and 7 are section views taken along line 6-6 and 7-7 of FIG. 5, respectively (note that FIG. 5, showing a quarter of the pallet 10, is already sectioned and broken away along those lines). As shown, the mating portions 32 (shown in phantom) are melted during a vibration welding process to connect the mating portions 32 to the upper planar portion 16 of the upper deck portion 12. The melted mating portions form a weld bead and flashing 32a, which secures the upper planar portion 16 to the ribs 26. Some of the flashing 32a flows into the recess 34 on the exterior of the peripheral wall 30 and is hidden from view by the peripheral lip 40 of the upper deck portion 12. Note that the recess 34 is deeper in FIG. 6 than in FIG. 7 and extends downwardly further in FIG. 6 than in FIG. 7. This indicates the direction of the relative movement between the upper deck portion 12 and lower deck portion 14 during the vibration welding process. The portion of the recess 34 in FIG. 6 accommodates the relative motion and accommodates some flashing 32a, while the portion of the recess 34 in FIG. 7 only provides some minimal clearance for parallel movement of the parts and accommodates some amount of flashing 32a.

(20) Also referring to FIG. 6, the reinforcing ribs 38 on the upper deck portion 12 extend downward between adjacent ribs 26 but are not secured to the lower deck portion 14.

(21) FIG. 8 is a top view of the pallet 10. FIG. 9 is a front view of the pallet 10. FIG. 10 is a side view of the pallet 10.

(22) In the example embodiment, the upper deck portion 12 is integrally molded as a single part from a thermoplastic material via injection molding. Similarly, the example lower deck portion 14 is integrally molded as a single part from a thermoplastic material via injection molding.

(23) In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. Alphanumeric identifiers on method steps are for convenient reference in dependent claims and do not signify a required sequence of performance unless otherwise indicated in the claims.