US 5,950,546 AGranted

Double deck fold-up pallet

AssigneeTriEnda Corporation

InventorsHenry F. Brown, Jamie E. Noble

Life of this patent

Estimating the term…

Loading patent…

Abstract

A single twin-sheet thermoformed plastic part has parallel bands of plastic forming fillets which allow stiff pallet deck segments to be folded after forming and locked together into a support structure with a planar upper deck spaced above a pallet lower deck with openings for lift truck tines. The lower deck has two segments joined by side stringers to the upper deck. Two central stringer segments extend along folding fillets from lower deck half segments to lock into place with the upper deck. The pallet is locked in its assembled configuration by a rod which passes through knuckles formed beneath the central stringers. The monocoque construction of the pallet provides for advantageous stiffness and load support capacity, while at the same time being economical to produce. For increased load-carrying capability, the pallet may be formed with a reinforcing substrate reinforced with a tubular steel insert. The pallet has interleaved step structure adjacent each plastic fillet which transfers vertical loads and also resists lateral deformation of the pallet.

Claims25

Dependent claims

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck, wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer and the first center stringer engages and is fastened to the second center stringer, and the first lower deck segment is connected to the second lower deck segment adjacent the first center stringer and the second center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck, wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, wherein the first center fold region has portions defining a plurality of knuckles, and the second center fold region has portions defining a plurality of knuckles which interleave with the first center fold region knuckles, and wherein a rod is inserted through the interleaved knuckles to prevent the separation of the first center stringer from the second center stringer.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment and along a first upper plastic fold region from the upper deck wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment. the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, wherein the upper deck has at least one downwardly opening channel, and wherein each center stringer has at least one protruding bayonet with portions defining a concave recess, such that adjacent bayonets extend within the upper deck channel such that the concave recesses face one another, and wherein a rod pierces a wall in the upper deck and passes through the concave recesses in the center stringers to restrain escape of the center stringers from the channel.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck, wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer and the first lower deck segment is connected to the second lower deck segment adjacent the first center stringer and the second center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, and wherein the upper deck has at least one downwardly opening channel, and wherein each center stringer has portions which protrude into the channel, and wherein a rod pierces a plurality of walls in the upper deck and passes through the center stringer protruding portions to restrain escape of the center stringers from the channel.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck. wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, wherein interlocking teeth are formed on the side stringers across the fold regions from teeth formed on the upper deck, such that the upper deck teeth engage with the stringer teeth to carry vertical loads from the upper deck to the stringers, and to resist lateral loads.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck, wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, wherein interlocking teeth are formed on the side stringers across the fold regions from teeth formed on the lower deck segments, such that the lower deck segment teeth engage with the stringer teeth to carry vertical loads from the stringers to the lower deck segments, and to resist lateral loads.

5 more elements

A pallet comprising:

a twin-sheet thermoformed upper deck, having a generally planar top surface;
a first twin-sheet thermoformed lower deck segment;
a second twin-sheet thermoformed lower deck segment, wherein the first lower deck segment and the second deck segment together comprise a lower deck which is disposed beneath and substantially parallel to the upper deck;
a first twin-sheet thermoformed side stringer extending along a first lower integral plastic fold region from the first lower deck segment, and along a first upper plastic fold region from the upper deck, wherein the first lower plastic fold region is substantially parallel to the first upper plastic fold region;
a second twin-sheet thermoformed side stringer extending along a second lower integral plastic fold region from the second lower deck segment, and along a second upper integral plastic fold region from the upper deck, wherein the second lower plastic fold region is substantially parallel to the second upper plastic fold region;
a first twin-sheet thermoformed center stringer extending along a first center fold region from the first lower deck segment, the first center stringer having portions which engage with the upper deck, such that the first center stringer is substantially parallel to the first side stringer and the second side stringer;
and
a second twin-sheet thermoformed center stringer extending along a second center fold region from the second lower deck segment, the second center stringer having portions which engage with the upper deck, such that the second center stringer is substantially parallel to the first side stringer and the second side stringer, and wherein the second center stringer extends in close relationship to the first center stringer, the upper deck, the first lower deck segment, the second lower deck segment, the first side stringer, the second side stringer, the first center stringer, and the second center stringer are formed as a single twin-sheet thermoformed part and are assembled by folding into a pallet, wherein the center stringers are connected to the lower deck segments by a plurality of bendable strips of plastic, and wherein the bendable strips extending from the the first lower deck segment are positioned adjacent the bendable strips extending from the second lower deck segment, and the bendable strips wrap around a connecting member which extends therebetween, the connecting member thereby preventing the first center stringer from separating from the second center stringer.

5 more elements

A pallet employing monocoque structure comprising:

a twin-sheet thermoformed upper deck, having a substantially planar top surface defining the structure outer fiber;
a twin-sheet thermoformed lower deck, comprised of two adjacent lower deck segments spaced parallel to and beneath the upper deck;
a first twin-sheet thermoformed side stringer, which extends between the upper deck and the lower deck;
a second twin-sheet thermoformed side stringer, which extends between the upper deck and the lower deck, wherein the first side stringer and the second side stringer are fixed to both the upper deck and the lower deck to transfer loads from the upper deck to the lower deck and to resist lateral loads;
two twin-sheet thermoformed center stringers which are positioned laterally between the first side stringer and the second side stringer and which extend between the upper deck and the lower deck, wherein one of the two center stringers extends from each of the two adjacent lower deck segments, the two center stringers being connected together at the lower deck;
and
interlocking structure formed on the upper deck which engages with protruding structure on the two center stringers to resist displacement of the center stringers with respect to the upper deck.

4 more elements

Dependencies are inferred from the claim text.