CA2147890A1

CA2147890A1 - Plastic pallet assembly

Info

Publication number: CA2147890A1
Application number: CA 2147890
Authority: CA
Inventors: Brandon L. Pigott; Schuyler F. Pigott; Peter S. Pigott; Maurice J. Pigott
Original assignee: Individual
Current assignee: Individual
Priority date: 1992-10-15
Filing date: 1993-10-14
Publication date: 1994-04-28
Also published as: WO1994008861A1; JPH08502463A; AU677253B2; EP0663882A1; AU5360194A

Abstract

A plastic pallet (10) is disclosed that comprises a generally rectanuglar pallet base (20), a generally rectangular pallet deck (100) and a plurality of connectors (11) interconnecting the base and the deck. The base (20) includes a pair of side members (31), a pair of end members (32) and a pair of cross members (33, 34). The deck (110, 210) is generally rectangular and has a planar outer surface (122, 222) with perimeter reinforcement means and an inner surface (121, 221) with a reinforcement structure pro-jecting outwardly therefrom.

Description

~ O 94/08861 _~ _ 214 7 8 9 D PCr/US93/09818 PLA STIC PA LLET A S SF~R! Y

D E S C R I P T ~ O N
Technical Field The present invention relates to pallets for storing and transporting goods, and more particu-larly to a pallet that comprises a unitary base and a unitary deck that are connected by a plurality of connectors. The pallet can be easily assembled for supporting goods and easily ~;c~sembled for trans-portation and storage.
~ackqround Prior Art It is customary to transport goods and to store goods on pallets. Palletized goods are maintained in a position above the flooring which can be very advantageous in areas where there is flooding or where the condition of the flooring is either rough or of concern. St~n~rd pallets are particularly useful in materials handling because SUBS~E SHE~T (RULE ~&) W 0 94/08861 P(~r/Us93/098t8 21478~0 -2-forklift equipment can maneuver the pallets by inserting their forklift tines into channels pro-vided by the pallet. Typically, pallets are con-structed of wood. In the past, wooden pallets have provided advantages of economy, simplicity and durability, principally because of the lack of other suitable materials. However, wooden pallets are extremely heavy and require costly hand labor in their fabrication.
In the past decades, disposable pallets have been proposed and, with the growth of the plastics industry, a wide variety of plastics have been investigated to determine their suitability for use in producing pallets. Plastic pallets can easily be molded and are stronger and lighter in weight than wooden pallets. They can also now be made with recyclable materials. Furthermore, plastic pallets are more durable than wooden pallets.
A recent plastic pallet that is light in weight, durable, capable of ~u~o~ing heavy loads and is easy to manufacture and have a i~; -number of parts that are preferably interchangeable are disclose~ in U.S. Serial No. 644,928 ~iled January 23, 1991, for a PLASTIC PALLET WITH DECK
ASSEM~3LY and in U.S. Patent No. 4,843,976 for a PLASTIC PALLET. The pallets and connectors dis-closed in this patent and application have proven to be highly sllccec~ful. In an effort to improve thereon, to reduce costs and weight of the pallets and to increase strength yet not decrease durabi-lity, the pallet of the present invention was dveloped. The present pallet is useful in material handling and designed for use with forklift equip-mnt.

SU8SrlTUrE SHEET (RULE ~

~o g4/0~6l -2 1 4 7 8 9 0 PCT/US93/09818 Summary of the Invention The present invention comprises a pallet base for use in combination with a second pallet base or, preferably, a pallet deck and a plurality of connectors. The pallet base is interconnected to the second pallet base or deck by the connectors.
According to a first aspect of the present invention, the pallet base has two surfaces, namely an inner surface facing the interior of the assem-bled pallet and an outer surface facing outwardlyfrom the assembled pallet. The base includes a pair of substantially parallel side members, with a plurality of openings therein for receiving the connectors. The side members are hooked-shaped in cross-section. The concave surface of the side members is the outer surface. It further includes a pair of substantially parallel end members that are substantially perpendicular to the side members and connected to the side members, with a plurality of openings therein for receiving the connectors.
The end members are also hooked-shaped in cross-section. Again, the concave surface of the end members is the outer surface. A first cross mem-ber, with a plurality of openings therein for receiving connectors, is disposed approximately halfway between the two end members and is connec-ted to the end members. The first cross member is U-shaped in cross section with the concave surface thereof being the outer surface. A second cross member, without any openings therein for receiving the connectors, is disposed approximately halfway between the two side members and is connected to the side members. Tha second cross member is also U-shaped in cross section with the concave surface being the outer surface.

SUBSrl~llE SHEET (RULE ~) 2 1 ~ 7 8 9 0 PCT/US93/09818 i The inner surface of the base has inner rein-forcement elements projecting therefrom that are a plurality of spaced apart transverse inner ribs.
The opposed outer surface has outer reinforcement elements projecting therefrom that are a plurality of spaced apart transverse outer ribs.
According to another aspect of the present invention, the pallet base further including a generally X-shaped outer rib wherein the first cross member intersects the second cross member and the side members include a generally V-shaped outer rib wherein the second cross member intersects thereto. The openings are formed by sleeves at-tached to the end, side and first cross members by spokes with each sleeve having an outer recessed aL~I ~nt for supporting a portion of the connector.
The pallet base also has a circular support wall projecting outwardly from the outer surface adja-cent each of the corner connector openings.
According to further aspects of the present invent-on, two pallet bases are disclosed for interconnecting with the pallet base by a plurality of connectors. Each of the bases are generally rectangular and have a first side, an opposed second side, a first end and an opposed second end.
The bases further have a substantially planar outer surface with perimeter reinforcement means. The perimeter reinforcement means including a perimeter end wall and at least one intermediate inclined end wall with the one inclined end wall having a drain therein.
I~ the first embodiment, the end perimeter reinforcement means includes a substantially verti-cal perimeter end wall and a first inclined end wall integral with a second inclined end wall. The SUBS~lTUrE SHE~T (RULE ~

21478gO
094/0886l ~ PCr/US93/098l8 ~ first inclined end wall includes a drain. The side perimeter reinforcement means includes a substan-tially vertical perimeter side wall and a first inclined side wall integral with a second inclined side wall. The first inclined side wall includes a drain. Spaced and parallel intermediate side walls are integral with and bridge the perimeter end wall and the planar section of the outer surface, and spaced and parallel intermediate end walls are integral with and bridge the perimeter side wall and the planar section of the outer surface. Both the side and the end perimeter reinforcement means are hooked-shape in cross-section.
In the second embodiment, the end perimeter reinforcement means includes a substantially verti-cal first perimeter end wall and a substantially vertical second perimeter end wall connected by an integral inclined end wall. The inclined end wall includes a drain. Similarly, the side perimeter reinforcement means includes a substantially verti-cal first perimeter side wall and a substantially vertical second perimeter side wall connected by an integral inclined end wall. The inclined side wall includes a drain. Spaced and parallel inter-med~ate side walls flush with the outer surface are integral with and bridge the first perimeter end wall and the second perimeter end wall, and spaced and parallel intermediate end walls flush with the outer surface are integral with and bridge the first perimeter side wall and the second perimeter side wall.
Both dec~s have an inner surface with a rein-forcement structure projecting outwardly therefrom.
The reinforcement structure includes a plurality of 35 generally rectangular cells formed by a plurality SU~SrlTUrE SHET (RULE ~

~ 1 s--W O 94/08861 PC~r/US93/09818 ~ , ~1~78~ -6-of parallel end walls and a plurality of side walls. Most of the cells include apertures for drainage. Moreover, the two decks have a first row of openings adjacent the first side of the deck, a second row of openings adjacent the second side of the deck, and an intermediate row of openings parallel to and ~;sFo~D~ between said first row and said second row of op~n;ngs, all for receiving the connoctors. There is also a centrally located side lo wall generally bisecting the cells along the third row of openings.
The openings in the decks and the base are formed by sleeves attached by spokes, each said sleeve having an outer recessed abutment for sup-porting a portion of the connector. Adjacent the openings at the corners of the deck are circular side support walls.
In the first embo~i -r-t of the deck, the cells diagonally adjacent the openings at the corners of the deck include diagonal intermediate cross walls, dia50nal intermediate cross walls and adjacent gussets. In addition, the cells diagonally adja-cent the cells including diagonal intermediate cross members have four inclined cross walls.
Also, select cells between the openings in the third row of openings include inclined cross walls.
Finally, the end wall adjacent the perimeter end wall has gussets attached thereto.
Second and third embodiments of the pallet are also shown.
Other advantages and aspects of the present invention will become apparent upon reading the following description of the drawings and detailed description of the invention.

SU8SrlTUrE SHE~T (RULE

~ O 94/08861 2 ~ 4 7 8 9 0 PC~r/US93/09818 - Brief ~escri~tion of Drawinqs Figure 1 is a top perspective view of a first embodiment of a plastic pallet made in accordance with the teachings of the present invention com-S prised of a base, a deck and a plurality of connec-tors;
Figur~ 2 is a top plan view of the base of the pallet of Figure 1;
Figur~ 3 is a bottom plan view of the base of Figur~ 2;
Figure 4 is a cross-sectional view along line 4-4 in Figur~ 2;
Figure 5 is a cross-sectional view along line 5-5 in Figure 2;
Figure 6 is a cross-sectional view along line 6-6 in Figure 2;
Figure 7 is a cross-sectional view along line 7-7 in Figure 3;
Figure 8 is a cross sectional view along line 8-8 in Figure 3;
Figure 9 is a cross-sectional view along line 9-9 in Figure 2;
Figure 10 is a top plan view of a first em-bodiment of a deck of the pallet of Figur~ 1;
Figure 11 is a bottom plan view of the deck of Figure 10;
Figure 12 is a cross-sectional view along line 12-12 in Figure 11;
Figure 13 is a cross-sectional view along line 13-13 in Figure 11;
Figure 1~ is a cross-sectional view along line 14-14 in Figur~ 11;

SV~ JtE SHEET (RULE ~6 W O 94/08861 P~r/US93/09818 2 1 4 7 8 ~ 0 -8-Figure 15 is a cross-sectional view along line 15-15 in Figure 11;
F~gure 16 is a cross-sectional view along line 16-16 in F~gure 11;
~igur~ 17 is a top plan view of a second embodiment of a deck of the pallet of Figure 1;
F~gure 18 is a bottom plan view of the deck of Figur~ 17;
Figure 19 is a cross-sectional view along line 19-19 in Figur~ 18;
Figure 20 is a cross-sectional view along line 20-20 in Figur~ 18;
Figure 21 is a cross-sectional view along line 21-21 in Figure 18;
Figur~ 22 is a cross-sectional view along line 22-22 in Figur~ 18;
Figur~ 23 is a cross-sectional view along line 2 3 -2 3 in Figur~ 18;
Figuxe Z~ is a perspective top view of a ~eco~ embodiment of a plastic pallet, comprised of a base, a deck and a plurality of connectors;
Figure 25 is a top plan view of the deck of the pallet of Figure 2~;
Figure 26 is a right elevation view of the 25 pallet of Figur~ 2~ with the left, front and rear elevation views ~eing the same;
Figure 27 is a bottom plan view of the base of the pallet of Figur~ 2~;
Figur~ 28 is a perspective top view of a third embodiment of a plastic pallet, comprised of a base, a deck and a plurality of connectors;
Figure 29 is a top plan view of the deck of the pallet of Figure 28;
Figur~ 30 is a bottom plan view of the base of the pallet of Figure 28;

SUBSr~TUI E Sl JE~T (RULE

~ vo 94/08861 214 7 8 9 0 Pcr/usg3/098l8 Figure 31 is a front elevation view of the pall~t of Figure 28 with the rear elevation view being a mirror image thereof; and, Figure 32 is a right elevation view of the pallet of Figure 28 with the left elevation view being a mirror image thereof.
~etailed ~escription While this invention is susceptible of embodi-ment 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 embodiments illus-trated. ~
A. The Pallet Assembly Figur~ 1 of the drawings shows a plastic pallet, generally designated by reference numeral 10, having three primary components. The compo-nents are a base 20, a deck 100 and a plurality of connectors 11. The connectors 11 that interconnect the deck and base are specially designed so that the pallet can be assembled without the need for any specially designed tools. The plastic pallet is designed such that the connectors can be snap fitted onto the decks.
The details of the connectors are disclosed and claimed in the invention by the same inventors of the present invention, U.S. Patent No. 4,843,976 for a PLASTIC PALLET, which is incorporated herein by reference.
In the preferred embodiment, the pallet incor-porates twelve (12) connectors 11. Both the deck and the base have openings which define surrounding SUBS~TUTE SHE~T(RULE ~

W O 94/08861 ~ PC~r/US93/09818 2147890 -lO-abutments that are recessed below the exposed surface and the connectors have flexible tangs that have barbs which engage the abutments. The pallet 10 has opposed sides 1~ and opposed ends 14. In the illustrated embodiment, the connectors are shown positioned at the four corners of the base and dec~
members and between each of the corners along the ends 14 of the pallet as well as two rows between each of the corners along the sides 13 of the pallet. The connectors 11 are positioned so that forklift tines can be inserted into side channels 15 and end channels 16 for lifting and moving the assembled pallet and the palletized goods.
B. The Base The base 20 of the present invention, shown in detail in Figures 2-9, is used below the deck loo and in use generally rests on the ground or floor. Because goods are not normally placed on the bacQ 20, it i~ not a flat, continuo~s sllrface, rather it is much like a frame structure. The base has two surfaces, namely an inner surface 21 and an outer surface 22. The outer surface 22 is the surface that faces out from the pallet; specific-ally the surface that faces down and contacts the ground or floor when the pallet is constructed.
The inner surface 21 is the surface facing the inside of the pallet, i.e., the side that the co~nectors are attached to. The inner surface 21 is shown in Figure 2 and the outer surface 22 is shown in Figure 3.
The base 20 is generally rectangular in shape.
It has a first side 23, an opposed second side 24, a first end 25 and an opposed second end 26. The base structure itself includes a pair of substan-tially parallel side members 31 with a plurality of SUBSrlTUrE SHEET (RULE ~

~ 094/08861 2 1 ~ 7 8 9 3 PCT/US93/09818 , .--i1--openings 17 therein for receiving the connectors11. A pair of substantially parallel end members 32 that are substantially perpendicular to the side members and connected to the side members are provided. Like the side members 31, the end mem-bers have a plurality of openings 17 therein for receiving the connectors 11.
A first cross member 33 with openings 17 for receiving the connectors 11 is disposed between the end members 32 and is connected to the end members.
A second cross member 33 with openings 17 for receiving the connectors 11 is disposed between the side members 31 and is connected to the side mem-bers.
Turning to Figure 6, there is shown cross section of an end member 32, which is similar to a side member 31. The end members 32, like the side members 31, are hooked-shaped in cross-section. In particular, at the first end 25, the end member has a horizontal portion 34 which is integral with an upwardly and inwardly projecting portion 35, which, in turn, is connected to a second horizontal por-tion 36. This second horizontal portion 36 is positioned above the first horizontal portion 34 adjacent the first end 25. The second horizontal portion 36 terminates with a vertical portion 37.
Accordingly, the concave surface formed by the upwardly and inwardly projecting portion 35, second horizontal portion 36 and vertical portion 37 of the end members 32 (and also side member 31) is the outer surface 22.
The inner surface 21 is contoured with inner reinforcement elements projecting outwardly there-from. These inner reinforcement elements are a plurality of spaced, parallel transverse inner ribs SUBST ~E SHE~T (RULE ~

W O 94/08861 ',~ PC~r/US93/09818 ~
2147~90 -12-38 integral with the inner surfaces of the first horizontal portion 34, upwardly and inwardly pro-jecting portion 35 and the second horizontal por-tion 36. The inner surface 38a of the transverse inner ribs 38 and act as guides or ramps for the forklift tines. Thus, if a tine hits the inclined surface, rather than pushing the pallet, it will slide along the incline to its proper position.
Similarly, the opposed outer Qurface 22 is con-toured with outer reinforcement elements projectingtherefrom. These outer reinforcement elements are a plurality of transverse outer ribs 39 that span the outer concave surface of the side or end mem-bers.
Turning to Figure s, there is shown a cross-section o~ a second cross member 34. The second cross ~ ~ 34, like the first cross ~^ ~r 33, is U-shaped in cross section. In particular, at the sides it has horizontal portlons 41 whlch are integral with upwardly and inwardly projecting portions 42 which, in turn, are connected to a second horizontal portion 43. This second horizon-tal portion 43 is positioned above the first hori-zontal portions 41 adjacent the sides. Thus, the concave surface formed by the upwardly and inwardly projecting portions 42 and second horizontal por-tion 43 is the outer surface 22.
The inner surface 21 of the cross members 33,34 are contoured with inner reinforcement ele-ments projecting outwardly therefrom that arespaced, parallel transverse inner ribs 38 integral with the inner surfaces of the first horizontal portion 41, upwardly and inwardly projecting por-tions 42 and second horizontal portion 43. Simi-larly, the opposed outer surface 22 is contoured SU8SrlTUrE SHE~T (RULE ~6~

~ 094/08861 2 1 4 7 8 9 0 PCT/US93/09818 with outer reinforcement elements projecting there-from that are transverse outer ribs 39 that span the outer concave surface of the cross members.
Snown in Figure~ 2 and 3, the side, end and cross members includ~ webs 40 at the points of their joining one another for additional strength.
Shown further in Figure 3, the outer surface 22, additional support ribs are provided. Specifi-cally, the side members 31 include a generally V-shaped outer rib 44 at the junction of where the second cross member intersects the two side mem-bers. In addition, the outer surface 22 includes a generally X-shaped outer rib 4S at the junction where the first cross member 33 intersects the second cross member 34.
Openings 17 for the connectors 11 are formed by sleeves and spokes built into the end, side and first cross member. In practice it has been found that twelve (12) openings are sufficient. There are, in fact three rows of openings, the first row of openings being in the first side member 23, the second row of openings being in the second side member 24, and the intermediate row, or third row, of openings being parallel to and disposed between the first row and the second row of openings in the first cross member 33. Each row has an opening at the ends (in the corners for the first and second rows and in the center of the end members 32,33 for the third row) and two intermediate openings.
As clearly shown in Figures 2, 3 and 4, the base 20 has openings 17 that are adapted to receive tangs of the connectors. The openings 17 are surrounded by outer recessed abutments 51 that are recessed below the plain of the adjacent outer surface 66 of the base. The outer recessed abut-SU8Sr~E SHE~T (RULE ~) w o 94/08861 ~ P~r/US93/09818 ~1 4 78g ~ -14-ments 51 are defined by an inner sleeves 52 which is cor~cted by spokes 53 to an outer sleeve 54.
The outer sleeve 54 is connected by a second spoke 55 to a third sleeve 56 formed into the base. The 5 connectors can t~us be snapped into the base, on the inner surface, by applying axial force to the conn~ctors so that the barbs of the connectors will snap into position onto the outer recessed abutment 51. With this construction, the barbs will not 10 extend out beyond the plain of the outer surface.
After all of the connectors are assembled on one base, the deck is positioned as shown in Figure 1 and a force is applied to the outside surface of the deck to complete the assembly of the plastic 15 pallet.
Shown in Figure 3 3 and ~, the pallet base has a circular support wall 57 projecting outwardly from the outer surface 22 adjacent each of the corner connector openings.
C. The First ~eck In the preferred embo~i ^nt, shown in Figure 1, the base 20 is connected, via connectors, to a deck 100. It is the deck that the goods are placed on. Two deck embodiments are disclosed, the first embodiment in Figures 10-16 and the second embodiment in Figure~ 17-23. Figure 10 of the drawings shows a first deck 110 of the present invention. The deck 110 has two surfaces, namely an inner surface 121 (Figur~ 11) and an outer surface 122 (Figur~ 10). The outer surface 122 is the surface that faces out from the pallet; specif-ically it is the surface that faces up and contacts the g~ods being palletized. The inner surface 121 is the surface facir.g the inside of the pallet, i.e., the side that the connectors are attached to.

SUBSrlTUI E SHE~T (RULE ~

094~08861 ~ 1 ~ 7 8 9 0 PC~r/US93/09818 The deck 110 is generally rectangular in shape. It has a first side 123, an opposed second side 124, a first end 125 and an opposed second end 126. The outer surface 122 iS substantially planar and includes perimeter reinforcement means. The end perimeter reinforcement means (Figure 13) includes a substantially vertical perimeter end wall 131 and a first inclined end wall 132 integral with a C~con~1 inclined end wall 133. The first inclined end wall 132 includes a drain 134. Spaced and parallel intermediate side walls 135 are inte-gral with and bridge the perimeter end wall 131 and the planar section of the outer surface. Simi-larly, the side perimeter reinforcement means (Figur ~ 14) includes a substantially vertical perimeter side wall 141 and a first inclined side wall 142 integral with a second inclined side wall 143. The first inclined side wall 142 includes a drain 144. Spaced and parallel intermediate end walls 145 are integral with and bridge the perime-ter side wall 141 and the planar section of the outer surface. Both the side and the end perimeter reinforcement means are hooked-shape in cross-section. The concave surface of the reinforcement means is the outer surface 122. The first inclined end walls 132 and first inclined side walls 142 act as guides or ramps for the forklift tines. Thus, if a tine hits the inclined wall, rather than pushing the pallet, it will slide along the incline to its proper position.
The inner surface 121 of the deck has a rein-forcement structure that projects outwardly there-from. This reinforcement structure includes a plurality of cells 151 formed by a plurality of 3S parallel end walls 152 and a plurality of side SU8S~l~JTE SHEET (RULE ~

WO94/08861 PCT~US93/098t8 ~
~ ~ 47% 9 0 -16-walls 153. The cells 151 are substantially rectan-gular and, apart from the perimeter cells 151a, the cells 151 are approximately the same size. The matrix formed by these end walls 152 and side walls 153 is shown in Figure 11. Most of the perimeter cells 151a include a second end wall 152a between the end walls 152 and a second side wall 153 (Figure 13) a between the side walls 152. Gussets 157 are further provided adjacent the second end walls 152a and second side walls 153a in the cells 151 adjacent the perimeter cells with the second walls. The gussets 157 are perpendicular the end walls 152.
As discussed previously, there are preferably twelve (12) openings in both the base and the deck for receiving the connectors. The openings are designated with the reference number 111. In the deck 110, . there is a f irst row of openings 112 adjacent the first side 123, a second row of open-ings 113 adjacent the second side 124 of the deck and an intermediate row of openings 114 parallel to and disposed between the first row 112 `and the second row 113 of openings.
Like the base, openings 111 in the base 110 for the connectors 11 are formed by sleeves and spokes built into the deck. Shown in Figure 12, the deck has openings 111 that are adapted to receive tangs of the connectors. The openings 111 are ~uLLour~ded by outer recessed abutments 161 that are recessed below the plain of the adjacent outer surface 122 of the deck. The outer recessed abut-ments 161 are defined by an inner sleeves 162 which is connected by spokes 163 to an outer sleeve 164.
The outer sleeve 164 is connected by a second spoke 165 to a third sleeve 166 formed into the deck. The SU~SrlTUrE SHEET (RULE ~

~ 094/08861 2117 8 9 0 PCr/US93/098l8 connectors can thus be snapped into the deck, on the inner surface, by applying axial force to the connectors so that the barbs of the connectors will snap into position onto the outer recessed abutment 161. With this construction, the barbs will not extend out beyond the plain of the outer surface.
After all of the connectors are assembled on one r deck, the base can be positioned as shown in Figure 1 and a force is applied to the outside su-face of the deck to complete the assembly of the plastic pallet.
As further seen in Figur~ 11, for added strength there is a centrally located central side wall 154 generally bisecting the cells 151 along the third row of openings 114. Moreover, it should be noted that most of the cells 151 include aper-tures 155 for drainage and to reduce the amount of material used. To avoid the problem of having goods falling through the deck, the apertures are not large.
Shown in Figures 11 and 1~, the pallet deck has a circular support wall 158 projecting outward-ly from the inner surface 121 adjacent each of the corner connector openings 111. Spokes 158a project inwardly from the circular support wall 158 and terminate at a circular sleeve 158b. On the oppo-site surface, namely the outer surface 122, of the circular support wall 158, spokes 158a and sleeve 158, there is a circular recess for receiving rubber pads 159a.
Turning again to Figure 11, the cells 151 diagonally adjacent said openings 111 at the cor-ners of the deck include a diagonal intermediate cross wall 171. These cells with the diagonal intermediate cross wall 171 further include an SUBSTlTUrE SHEET (RULE ~B~

WO94/08861 ; ~ PCT/US93/09818 2~ 47~90 -18-adjacent gusset 157 but do not include an aperture therein. The cells 151 diagonally adjacent these cells with a diagonal intermediate cross member 171 include four inclined cross walls 172 projecting inwardly from the corne.s of t~e cell. As also seen in the figure, select cells 151 between the openings 111 in the third, center row of openings 114 also include inclined cross walls 173 project-ing inwardly from the corners of the cell.
Figures 11 and 15, show the perimeter rein-forcement structure and cells disposed between the two perimeter center openings 111. Because a forklift tine is not intended to enter the pallet adjacent this section, there is neither a first or second inclined side walls nor a intermediate end wall. Rather, there is a cubstantially vertical cecon~ perimeter side wall 174 and a closely spaced parallel third perimeter side wall 175. A drain 134 is disposed between them.
Additional central diagonal walls 176 (Figur~
11) also project towards the center of the base from the two perimeter center openings 111 for added strength.
D. The Second ~eck A second deck embodiment is shown in Figures 17-23. Figur~ 17 of the drawings shows the second deck 210 of the present invention. The deck 210 has two surfaces, namely an inner surface 221 (Figur~ 18) and an outer surface 222 (Figure 17).
The outer surface 222 is the surface that faces out from the pallet, facing up and contacting the goods being palletized. The inner surface 221 is the surface facing the inside of the pallet and the base, i.e., the side that the connectors are at-tached to.

SUBSTITUTE SHEET (RULE ~

~ 094/08861 2 1 ~ 7% g O PCT/US93/09818 . .i . .

The deck 210 is generally rectangular in shape. It has a first side 223, an opposed second side 224, a first end 225 and an opposed second end 226. The outer surface 222 is substantially planar and also includes perimeter reinforcement means.
The end perimeter reinforcement means (Figure 20) includes a substantially vertical first perimeter end wall 231 and a -ubstantially vertical second perimeter end wall 232 connected by an integral inclined end wall 233. The inclined end wall 233 includes a drain 234. Spaced and parallel interme-diate side walls 235 flush with the outer surface 222 are integral with and bridge the first perime-ter end wall 231 and the second perimeter end wall 232. Similarly, the side perimeter reinforcement means (Figure 23) includes a substantially vertical first perimeter side wall 241 and a substantially vertical second perimeter side wall 242 connected by an integral inclined end wall 243. The inclined side wall 242 includes a drain 244. Spaced and parallel intermediate end walls 245 flush with the outer surface 222 are integral with and bridge the first perimeter side wall 241 and the second peri-meter side wall 242. The concave surface of the reinforcement means, or the cell formed by it, is the outer surface 222. The inclined end walls 233 and inclined side walls 243 act as guides or ramps for the forklift tines.
The inner surface 121 of the deck has a rein-forcement structure that projects outwardly there-from. This reinforcement structure includes a plurality of cells 251 formed by a plurality of parallel end walls 252 and a plurality of side walls 253. The cells 251 are substantially rectan-gular and, apart from the perimeter cells 251a, the SUBS~ E SHE~T (RULE ~

W O 94/08861 ~ 1 4 7 8 9 ~ PC~r/US93/09818 cells 251 are approximately the same size. The matrix formed by these end walls 252 and side walls 253 is shown in Figure 18.
There are twelve (12) openings 211 for receiv-ing the connectors. In the deck 210, like thefirst embodiment 110, there is a first row of openings 212 adjacent the first side 223, a second row of openings 213 adjacent the second side 224 of the dack and an intermediate row of openings 214 parallel to and disposed between the first row 212 and the second row 213 of openings.
Openings 111 in the base 210 for the connec-tors 11 are formed by sleeves and spokes built into the deck. Shown in Figure 19, the deck has open-15 ings 211 that are adapted to receive tangs of theconnectors. The openings 211 are surrounded by outer recessed abutments 261 that are recessed below the plain of the adjacent outer surface 222 of the deck. T~he outer recessed abutments 261 are defined by an inner sleeves 262 which is connected by spokes 263 to an outer sleeve 264. The outer sleeve 264 is connected by a second spoke 265 to a third sleeve 266 formed into the deck. The connec-tors can thus be snapped into the deck, on the inner surface, by applying axial force to the connectors so that the barbs of the connectors will snap into position onto the outer recessed abutment 261. With this construction, the barbs will not exter.d out beyond the plain of the outer surface.
After all of the connectors are assembled on one deck, the base can be positioned as shown in Figur~
1 and a force is applied to the outside surface of the deck to complete the assembly of the plastic pallet.

SUBSrlTUlE SHE~T (RULE

094/08861 2 1 1 7 ~ 9 ~ Pcr/us93/o9818 As further seen in Figure 18, for added strength there is a centrally located central side wall 254 generally bisecting the cells 251 along the third row of openings 214. Moreover, it should S be noted that most of said cells 251 include aper-tures 255 for drainage and to reduce the amount of material being used. To avoid the problem of having goods falling through the deck, the aper-tures are not large.
Shown in Figures 18 and 22, the pallet deck has a circular support wall 258 projecting outward-ly from the inner surface 221 adjacent each of the corner connector openings 211. Spokes 258a project inwardly from the circular support wall 258 and terminate at a circular sleeve 258b. On the oppo-site surface, namely the outer surface 222, of the circular support wall 258, spokes 258a and sleeve 258, there is a circular recess for receiving rubber pads 259 (Figure 17).
The perimeter reinforcement structure and cells disposed between the two perimeter center openings 211 are substantially vertical because a forklift tine is not intended to enter the pallet at this section.
A second embodiment of the plastic pallet 310 is shown in Figures 24-27. This second embodiment 310 also includes a base 320 and a deck 300 and is held together by a plurality of connectors 11.
A third embodiment of the plastic pallet 410 is shown in Figures 28-32 and includes a base 420 and a deck 400. ~t, too, is held together by a plurality of connectors 11.
The two pallet components, namely the base and the deck, are preferably injection molded from recycled material, such as polypropylene or similar SUBSrl~UrE SHE~T (RULE ~3 W O 94/08861 PC~r/US93/09818 2 1 4 7 8 9 ~ -22-thermoplastic material. Additionally, a pigment may be added to provide color combinations to suit the customer's needs.
Of course, the size and shape and the number of c~nn~ctors can be varied without departing from the spirit of the invention. Also, while identical decks have been shown and described, the decks could have different shapes or configurations.
It will be apprecia~ed that the simplicity of the plastic pallet reduces the inventory substan-tially since only two components are necessary.
Also, since the base or deck only requires recessed shoulders formed in wells, the molds for producing the large decks are greatly simplified which redu-ces the production costs.
The intricate design of the connectors hasseveral distinct advantages. The design is such that all external forces are transmitted to the cen~er o~ ~hê ~ore, whi~h will with~tand the grea-test force without destruction. Furthermore, the connectors are configured so that they are formed as one piece in a single stage mold to reduce the cost. Since the connectors and the decks are preferably injection molded from recycled plastic, the costs are further reduced.
Another significant advantage of the plastic pallet is that the connectors can easily be sepa-rated should one the connectors become damaged.
This can be accomplished by the owner without return of the pallet assembly to the manufacturer.
While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of pro-SU8SrlTUrE SHEET (RULE ~

2~78~
o 94/08861 Pc~r/us93/09818 tection is only limited by the scope of the accom-panying Claims.

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SUBSl~T~TE SHEET~RULE ~f~

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Claims

PATENT CLAIMS

1. A pallet base (20) for use in combination with a second pallet base (20) or a pallet deck (100,110,210) and a plurality of connectors (11), the pallet base (20) having an outer perimeter, an inner surface (21) and an outer surface (22) and being interconnected to the second pallet base (20) or deck (100,110,210) by the connectors (11), said pallet base (20) further having a pair of substantially parallel side members (31) and a pair of substantially parallel end members (32) that are substantially perpendicular to said side members (31), both said side and said end members (31,32) having a plurality of openings (17) therein for receiving the connectors (11); a first cross member(33) disposed between and connected to said end members (32) and a second cross member (34) disposed between and connected to said side members (31), both said first and second cross members (33,34) having a plurality of openings (17) therein for receiving the connectors (11); said inner surface (21)having a plurality of spaced apart transverse inner ribs (38) projecting therefrom; and, said opposed outer surface (22) having a plurality of spaced apart transverse outer ribs (39) projecting therefrom, characterized by said side members (31) and said end members (32) being hooked-shaped in cross-section, said cross members (33,34) being U-shaped in cross section,

2. The pallet base (2)) as defined in Claim 1 characterized by said side members (31) and said end members (32) including a substantially horizontal first portion (34) forming the outer perimeter, a ramp portion (35), a substantially horizontal second portion (36) and a vertical portion (37), saidouter surface (22) of said ramp portion (35), said horizontal second portion (36) and said vertical portion (37) being concave.

3. The pallet base (20) as defined in Claims 1 and 2 characterized by said cross members (33,34) including a substantially horizontal second portion (43) having two sides with a ramp portion (42) and a substantially horizontal first portion (41) integral with each of said two sides of said horizontal second portion (43), the outer surface (22)of said ramp portions (42) and said horizontal second portion (43) being concave.

4. The pallet base (20) as defined in Claims 1 - 3 characterized by said openings (17) being formed by sleeves (52,54) attached to said end (32), said side (31) and said first cross members (33) by spokes (53,55), each said sleeve (52,54) having an outer recessed abutment (51) for supporting a portion of the connector (11).

5. The pallet base (20) as defined in Claim 1 - 4 characterized by further including a generally X-shaped outer rib (45) where said first cross member (33) intersects said second cross member (34) and further characterized by said side members (31) including a generally V-shaped outer rib (44) where said second cross member (34) intersects thereto and said openings (17) being formed by sleeves (52,54) attached to said end (32), said side (31) and said first cross member (33) by spokes (53,55), each said sleeve having an outer recessed abutment (51) for supporting a portion of the connector (11) .

6. A generally rectangular pallet deck (110,210) having an outer perimeter (123), a first side (123,223), an opposed second side (124,224), a first end (125,225) and an opposed second end (126,226) for use in combination with a second pallet deck (110,210) or a pallet base (20) and a plurality of connectors (11), the pallet deck (110,210) being interconnected to the second pallet deck (110,210) or base (20) by the connectors (11), said pallet deck (110,210) further having (a) a substantially planar outer surface (122,222) with perimeter reinforcement means; (b) an inner surface (121,221) with a reinforcement structure projecting outwardly therefrom; (c) a first row of openings (112,212) adjacent the first side (123,223) of the deck (110,210) for receiving the connectors (11); (d) a second row (113,213) of openings adjacent the second side (124,224) of the deck (110,210) for receiving the connectors (11); and, (e) an intermediate row of openings (114,214) parallel to and disposed between said first row and said second row of openings (112,113,212,213), characterized by said perimeter reinforcement means of said outer surface (122,222) including a substantially vertical perimeter wall (131,141,231,241) forming the outer perimeter and two adjacent inclined perimeter walls (132,133,142,143,232,233,242,243) joined at an apex, the outer surface (122,222) of said inclined perimeter walls (132,133,142,143,232,233,242,243) being concave, one said inclined perimeter wall (132,133,142,143,232,233,242,243) having a drain (134,144,234,244) therein, said reinforcement structure of said inner surface (121,221) including a plurality of cells (151,251) formed by a plurality of parallel end walls (152,252) and a plurality of side walls (153,253).

7. The pallet deck (110,210) as defined in Claim 6 characterized by each such cell (151,251) being substantially rectangular and approximately the same size.

8. The pallet deck (110,210) as defined in Claim 6 and 7 characterized by there being a centrally located side wall (154,254) generally bisecting said cells (151,251) along said intermediate row of openings (114,214).

9. The pallet deck (110,210) as defined in Claim 6 - 8 characterized by most of said cells (151,251) including an aperture (155,255) for drainage.

10. The pallet deck (110,210) as defined in Claim 6 - 9 characterized by said openings (111,211) being formed by sleeves (162,164,262,264) attached by spokes (163,263), each said sleeve (162,164,262,264) having an outer recessed abutment (161,261) for supporting a portion of the connector (11).

11. The pallet deck (110,210) as defined in Claim 6 - 10 characterized by said openings (111,211) adjacent the first and (125,225) and the second end (126,226) of the deck having circular side support walls (158,258) adjacent thereto.

12. The pallet deck (110) as defined in Claim 6 - 11 characterized by said cells (151) diagonally adjacent said openings (111) at the corners of the deck including diagonal intermediate cross walls (171).

13. The pallet deck (110) as defined in Claim 6 - 12 characterized by said cells (151) having diagonal intermediate cross walls (171) further including adjacent gussets (157) .

14. The pallet deck (110) as defined in Claim 6 -13 characterized by said cells (151) diagonally adjacent said cells (151) having diagonal intermediate cross walls (171) including four inclined cross walls (172).

15. The pallet deck (110) as defined in Claim 6 - 14 characterized by select cells (151) between said openings (111) in said intermediate row of openings (114) including inclined cross walls (173).

16. A plastic pallet (10) having a generally rectangular pallet base (20), a generally rectangular pallet deck(100,110,210), and a plurality of connectors (11) interconnecting said base (20) and said deck (100,110,210), the pallet base (20) including a pair of substantially parallel side members (31) with a plurality of openings (17) therein for receiving said connectors (11); a pair ofsubstantially parallel end members (32) that are substantially perpendicular to said side members (31) and connected to said side members (31), said end members (32) having a plurality of openings (17) therein for receiving said connectors (11); a first cross member (33) disposed between and connected to said end members (32), said first cross member (33) having a plurality of openings (17) therein for receiving said connectors (11); a second cross member (34) disposed between and connected to said side members (31); a contoured inner surface (21) with inner reinforcement elements projecting therefrom; and, an opposed contoured outer surface (22) with outer reinforcement elements projecting therefrom, and the pallet deck (110,110,210) including a first side (123,223), an opposed second side (124,224), a first end (125,225) and an opposed second end (126,226); a substantially planar outer surface (122,222) with perimeter reinforcement means; an inner surface (121,221) with a reinforcement structure projecting outwardly therefrom; a first row of openings (112,212) adjacent said first side (123,223) of said deck (110,210) for receiving said connectors (11); a second row of openings (113,213) adjacent said second side (124,224) of said deck (110,210) for receiving said connectors (11); and, an intermediate row of openings (114,214) parallel to and disposed between said first row and said second row of openings (112,113,212,213) for receiving said connectors (11), characterized by said end members (32) and said side members (31) of said pallet base (20) are hooked-shaped in cross-section, the concave portion of the hook-shape being said outer surface (22), and said first cross members (33) and said second cross members (34) of said pallet base (20) are U-shaped in cross section, the concave portionof the U-shaped being said outer surface (22), said perimeter reinforcement means of said outer surface (122,222) of said pallet deck (110,210) including a substantially vertical perimeter wall (131,141,231,241) forming the outer perimeter and two adjacent inclined perimeter walls (132,133,142,143,232,233,242,243) joined at an apex, the outer surface (122,222) of said inclined perimeter walls (132,133,142,143,232,233,242,243) being concave, one said inclined perimeter wall (132,133,142,143,232,233,242,243) having a drain (134,144,234,244) therein,said reinforcement structure of said inner surface (121,221) of said pallet deck (110,310) including a plurality of cells (151,251)formed by a plurality of parallel end walls (152,252) and a plurality of side walls (153,253).

17. The pallet (10) as defined in Claim 16 wherein said inner reinforcement elements of said pallet base (20) are a plurality of spaced apart transverse inner ribs, and said outer reinforcement elements of said base are a plurality of spaced apart transverse outer ribs.

18. The pallet (10) as defined in Claim 16 and 17 characterized by said side members (31) of said pallet base (20) include a generally V-shaped outer rib (44) where said second cross member (34) intersects thereto, and a generally X-shaped outer rib (45) where said first cross member (33) intersects said second cross member (34).

19. The pallet (10) as defined in Claim 22, characterized by each such cell (151,251) of said pallet deck (110,210) is substantially rectangular and approximately the same size.

20. The pallet (10) as defined in Claim 26, characterized by there being a centrally located side wall (154,254) generally bisecting said cells (151,251 ) along said intermediate row of openings (114,214) in said pallet deck (110,210), and most of said cells (151,251) include an aperture (155,255) for drainage in said pallet deck (110,210).