Twin sheet pallet

A twin sheet plastic runner pallet comprising:

• a generally rectangular lower plastic sheet having parallel side walls, parallel end walls, at least three separate parallel upwardly opening longitudinally extending grooves extending continuously from end wall to end wall of the sheet and alternate downwardly opening longitudinally extending grooves extending continuously from end to end of the sheet and opening in the end walls of the sheet;
• and
• a generally rectangular upper plastic sheet having a generally planar top wall defining a generally rectangular platform surface and a plurality of longitudinally and laterally spaced protrusions extending downwardly from the top wall, opening upwardly in the platform surface, and nestingly and fusedly received in the upwardly opening continuous grooves in the lower sheet;
• the protrusions arranged in at least three parallel longitudinally extending rows with at least two longitudinally spaced protrusions in each row;
• each upwardly opening groove including a continuous fiat bottom wall, the bottom walls coacting to define a pallet footprint consisting of at least three separate, flat, laterally spaced parallel longitudinally extending runner surfaces extending from end to end of the pallet;
• at least two upwardly opening protrusions being nestingly and fusedly received in each upwardly opening groove;
• each upwardly opening protrusion including a bottom wall, longitudinally extending sidewalls, and end walls;
• the protrusions in each groove being positioned in the groove in longitudinally spaced relation with respect to each other and with respect to the end walls of the lower sheet so as to define longitudinally extending spaces in the groove between confronting end walls of adjacent protrusions and between protrusion end walls and the lower sheet end walls and so as to define a platform surface including continuous parallel longitudinal surfaces extending from end to end of the pallet between the upwardly opening grooves and continuous parallel lateral surfaces extending from side to side of the pallet proximate each end of the pallet as well as intermediate the ends of the pallet;
• the pallet further including laterally aligned slots in fused together sidewalls of the upwardly opening grooves and the upwardly opening protrusions to provide at least two laterally extending slots to allow lateral passage of the forks of a fork lift truck.

A plastic twin sheet runner pallet comprising an upper plastic sheet and a lower plastic sheet selectively fused to the upper sheet, characterized in that:

• the lower sheet has a generally rectangular configuration, including substantially parallel continuous outer longitudinal sidewalls and substantially parallel lateral outer end walls extending continuously between the outer longitudinal sidewalls to form a continuous rectangular outer perimeter wall defining a continuous peripheral upper edge extending continuously around the perimeter of the sheet, and includes at least three separate, parallel, upwardly opening longitudinally extending U-shaped grooves extending continuously from end wall to end wall of the sheet and at least two downwardly opening longitudinally extending U-shaped grooves interspersed between the upwardly opening grooves and extending continuously between and opening in the end walls of the sheet;
• the upper sheet has a generally rectangular configuration including a planar continuous downwardly facing surface extending around the entire perimeter of the sheet and is positioned over the lower sheet with the continuous downwardly facing planar surface fused to the continuous peripheral upper edge of the lower sheet to define a generally planar platform surface for the pallet;
• each upwardly opening groove includes laterally spaced longitudinally extending vertical sidewalls and a continuous flat bottom wall, the bottom walls coacting to define a pallet footprint consisting of at least three separate flat laterally spaced longitudinally extending parallel runner surfaces extending from outer end wall to outer end wall of the pallet;
• the upper sheet defines a top wall defining the platform surface and at least three parallel longitudinally extending and laterally spaced rows of upwardly opening U-shaped protrusions extending downwardly from the top wall with each row including at least two longitudinally spaced protrusions;
• each U-shaped protrusion includes laterally spaced and longitudinally extending vertical sidewalls, a bottom wall, and end walls, the upper sheet positioned over the lower sheet with a row of at least two protrusions positioned in each upwardly opening groove and the laterally spaced vertical sidewalls of each U-shaped protrusion fused respectively to the laterally spaced vertical sidewalls of a respective upwardly opening U-shaped groove and the bottom wall of each U-shaped protrusion fused to the bottom wall of a respective upwardly opening U-shaped groove to form at least two longitudinally spaced double thickness U-shaped wall structures in each groove with each double thickness wall structure formed at the interface of a protrusion and a respective upwardly opening groove and with each double thickness U-shaped wall structure including laterally spaced double thickness sidewall structures and a double thickness bottom wall structure;
• the pallet further includes laterally aligned cut-outs formed in the double thickness laterally spaced sidewall structures of each double thickness U-shaped wall structure, the cut-outs in the double thickness sidewall structures being laterally aligned to form at least two fork lift slots each extending laterally across the pallet from one outer longitudinal sidewall to the other outer longitudinal sidewall to provide firm engagement for the forks of a fork lift truck to preclude pal let tipping;
• the protrusions in each groove being positioned in the groove in longitudinally spaced relation to the lateral end walls of the lower sheet so as to define longitudinally extending spaces in the groove between confronting end walls of adjacent protrusions and between protrusion end walls and the lower sheet end walls and so as to define a platform surface including continuous parallel longitudinally extending surfaces extending from end to end of the pallet between the upwardly opening grooves and continuous parallel lateral surfaces extending from side to side of the pallet proximate each end of the pallet as well as intermediate the ends of the pallet;
• each downwardly opening groove being defined by a vertical side wait of an upwardly opening groove, a vertical side wall of an adjacent upwardly opening groove, and a flat top wall;
• the lower sheet further defining a series of knobs upstanding from each flat top wall;
• and
• portions of the top wall of the upper sheet overlying the knobs and being fused to the knobs to define a twin sheet wall construction overlying the downwardly opening grooves and positioned above the forklift slots.

A twin sheet, molded plastic, runner type industrial pallet with four-way forklift entry comprising:

• a base portion and an integral deck portion;
• the base portion comprising a generally rectangular plastic body having end walls with upper peripheral edges and including a plurality of parallel upwardly opening, continuous U-shaped sections forming parallel continuous runner legs, each of which is defined by opposed substantially parallel sidewalls joined at the bottom by a floor surface, each said runner leg extending fully between the end walls to define a pallet footprint consisting of three flat parallel, continuous and wholly separate runner leg floor surfaces extending from end wall to end wall;
• said base portion including bridge members extending between adjacent runner legs and integral therewith;
• said runner legs being spaced apart to define at least two downwardly opening first forklift openings extending the full length of the base portion between and through the end walls;
• said bridge members defining at least two seat surfaces located between and extending parallel to said runner legs and between said end walls;
• at least two metal beams disposed on said bridge members and extending in parallel between said end walls and over said forklift openings but below the upper peripheral edges of said end walls;
• the deck portion comprising a top deck sheet fused to the base portion and having formed therein at least two space apart parallel rows of generally rectangular downwardly extending U-shaped, walled depressions of a width and depth to nest into and contact the sidewalls and floors of the runner legs, and extend substantially from said upper peripheral edges to the runner leg floors such that the depressions are substantially wholly nested within the runner legs and between the at least two first forklift openings;
• each walled depression having an integral floor which rests on and is fused to a respective runner leg floor;
• and
• at least two parallel second forklift openings formed fully through the walls of the base portion legs and the depressions nestled within the legs, immediately below the beams and mediate the end walls but above the floors and at right angles to the downwardly opening first forklift openings so as to provide four-way forklift entry to the resulting pallet.

A method of making a reinforced twin-sheet plastic runner pallet with four-way entry comprising the steps of:

• molding a generally rectangular plastic base with three parallel U-shaped runner legs extending between end walls of the base, each leg having opposed side walls joined at the bottom by a floor surface, the legs spaced apart by upper bridge portions to define three parallel spaced-apart runner legs creating a pallet footprint consisting of three spaced-apart runner leg floor surfaces extending from end wall to end wall, the base further defining two parallel spaced apart downwardly opening grooves between grooves between the runner leg and grooves between the runner grooves between the runner legs grooves between the runner leg and opening in the end walls;
• placing reinforcement beams on the bridge portions and between the end walls;
• molding a plastic top with a top wall and two parallel rows of rectangular concavities with three concavities in each row and wherein the concavities in each row are spaced apart to match the spacing between the legs;
• nesting the concavities of the top into the base legs so the top overlies the beams and knitting the plastic of the concavities to the plastic of the legs;
• and
• forming two parallel, spaced-apart forklift openings fully through the sidewalls of the legs and the concavities.