Half size plastic pallet with deck pocket

Abstract

A pallet and a method of manufacturing a pallet are disclosed, the pallet comprising: a top deck divided into quadrants; and a plurality of pallet support feet joined to an underside of the top deck and forming openings below the top deck for receiving lifting members; the top deck comprising at least one deck pocket region in each quadrant on an underside thereof, and the thickness of the top deck having a curved portion in each deck pocket region to reduce the effect of top deck deflection on the ability of the lifting members to pass through the openings below the top deck.

Description

[0001] This application is a divisional application of patent application entitled "Half Size Plastic Pallets with Deck Pocket Areas" having a filing date of November 11, 2019, application number 201980074916.2,

[0002] This application is a divisional application of patent application entitled "Half Size Plastic Pallets with Deck Pocket Areas" having a filing date of November 11, 2019, application number 201980074916.2,

[0003] Related Patent Application

[0004] This patent application claims priority to provisional patent application number 62 / 760,218 filed November 13, 2018, which is incorporated herein in its entirety by this reference. TECHNICAL FIELD

[0005] The present disclosure relates to the field of pallets, and more particularly to half size plastic pallets. BACKGROUND

[0006] When displaying products for purchase by customers, retail stores often prefer to use fractional pallets. Typically, fractional pallets are one quarter to one half the size of full size pallets. Fractional pallets have a significantly smaller footprint, which allows retail stores to display a greater variety of products in the same size area as a full size pallet.

[0007] In addition, retail stores often prefer to use fractional plastic pallets instead of fractional wooden pallets.

[0008] Fractional plastic pallets are more aesthetically pleasing and more sanitary than fractional wooden pallets.

[0009] Even with current fractional plastic pallets, there is a need for fractional plastic pallets that can be easily moved by pallet handling equipment and that can achieve an aesthetically acceptable product display. Since the products to be carried by fractional plastic pallets can sometimes be relatively heavy, the load capacity of the pallet should not be sacrificed in order to provide ease of use. SUMMARY

[0010] A pallet includes a top deck divided into quadrants and pallet support feet joined to an underside of the top deck. The pallet support feet form an opening below the top deck for receiving a lifting member. The top deck includes at least one deck pocket area on an underside thereof in each quadrant, and a thickness of the top deck is reduced in each deck pocket area to reduce the effect of top deck deflection on the ability of the lifting member to pass through the opening below the top deck.

[0011] The at least one deck pocket area in each quadrant can include a hand grip opening. The at least one deck pocket area in each quadrant can have a rectangular shape.

[0012] At least one deck pocket in each quadrant can include a first and second deck pocket. Each quadrant can include a transition wall separating the first and second deck pocket, and the transition wall does not reduce the thickness of the top deck.

[0013] The underside of the deck can include exposed ribs, and at least one deck pocket in each quadrant includes the exposed ribs.

[0014] The top deck can include an outer perimeter region surrounding the at least one deck pocket, and the thickness of the top deck is not reduced in the outer perimeter region.

[0015] The top deck has a product support surface, and the product support surface includes openings extending to the underside. The openings form a grid pattern in at least one deck pocket in each quadrant. Each grid pattern can be symmetrical with grid patterns in other quadrants.

[0016] The top deck and each pallet support foot can include plastic.

[0017] Another aspect is directed to a method for manufacturing a pallet having deck pockets as described above. The method includes forming a top deck divided into quadrants, and forming pallet support feet. The pallet support feet are joined to an underside of the top deck forming openings underneath the top deck for receiving lifting members. Forming the top deck includes forming at least one deck pocket in each quadrant on an underside thereof, and reducing the thickness of the top deck in each deck pocket to reduce the effect of top deck deflection on the ability of the lifting members to pass through the openings underneath the top deck. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 is a top perspective view of a half-size plastic pallet in accordance with the present disclosure.

[0019] Figure 2 is Figure 1 is a bottom perspective view of the half-size plastic pallet shown in

[0020] Figure 3 is Figure 1 and 2 is a top perspective view of a pallet support foot of the half-size plastic pallet shown in

[0021] Figure 4 is Figure 1 and 2 is a top view of the pallet support foot shown in

[0022] Figure 5 is Figure 1 and 2 is a bottom view of the pallet support foot shown in

[0023] Figure 6 It is an insertion. Figure 3 A perspective view of the plug inside the reinforcing rod opening of the support leg of the tray shown.

[0024] Figure 7 yes Figure 1 The top perspective view of the top deck is shown.

[0025] Figure 8 yes Figure 7 The top view of the top deck is shown.

[0026] Figure 9 yes Figure 7 The above perspective view of one of the mounting points of the product display shown.

[0027] Figure 10 yes Figure 7 The image shows a bottom perspective view of the top deck.

[0028] Figure 11 yes Figure 7 The top view of the top deck is shown.

[0029] Figure 12 yes Figure 7 The diagram shows a side view of the top deck.

[0030] Figure 13 yes Figure 1 The side view of the half-size plastic tray shown.

[0031] Figure 14 yes Figure 13 The end view of the half-size plastic tray shown.

[0032] Figure 15 yes Figure 7 A partial view of the cable ring opening within the top deck shown.

[0033] Figures 16-21 yes Figures 13-14 Various views of the cable loop shown.

[0034] Figure 22 yes Figure 1 The side view shows a half-size plastic tray stacked with another half-size plastic tray.

[0035] Figure 23 yes Figure 22 The figure shows a side cross-sectional view of the stacked half-size plastic pallets.

[0036] Figure 24 It is configured as a dolly. Figure 7 The top perspective view of the top deck shown.

[0037] Figure 25 yes Figure 24a bottom perspective view of the illustrated tray.

[0038] Figure 26 is Figure 24 a side view of the illustrated tray.

[0039] Figure 27 is Figure 24 an end view of the illustrated tray.

[0040] Figure 28 is Figure 24 an overhead perspective view of the illustrated tray stacked with another tray.

[0041] Figure 29 is Figure 28 a side view of the illustrated stacked trays. DETAILED DESCRIPTION

[0042] The description is presented with reference to the accompanying drawings, which show example embodiments. However, many different embodiments can be used, and thus, the description is not to be taken in a limiting sense as to the particular embodiments described. Rather, the description is provided as illustrative of the broad aspects of the disclosure to enable this disclosure to be thorough and complete. Throughout the drawings, like numbers refer to like components.

[0043] Reference is first made to Figure 1 and 2 The illustrated half-size plastic pallet 20 includes a top deck 30 and three removable pallet support feet 40 coupled to the top deck. In the event that a pallet support foot 40 or the top deck 30 becomes damaged, since the pallet support feet 40 are removable from the top deck 30, this allows for easy repair of the half-size plastic pallet.

[0044] The three pallet support feet 40 include a center pallet support foot and a pair of outer pallet support feet. The pallet support feet 40 are configured to enable four-way insertion by pallet handling equipment such as a forklift or pallet jack. As discussed in detail below, the plastic pallet 20 is repairable, stackable, and includes product display attachment points.

[0045] The half-size plastic pallet 20 is 24 inches by 40 inches. While the features of the disclosed plastic pallet 20 are directed to a half-size pallet, these features can be used for plastic pallets of other sizes. For example, the size of the plastic pallet 20 can be reduced to a quarter-size, which is 24 inches by 20 inches. Even the size of the plastic pallet 20 can be increased to a full-size, which is 48 inches by 40 inches. To accommodate countries that use the metric system, these dimensions can be adjusted.

[0046] The top deck 30 includes an upper surface, referred to as a product support face 32, and an opposite lower surface, referred to as an underside 34. The top deck 30 has an exposed side extending between the product support face 32 and the opposite underside 34. The exposed side includes a spaced outer side 36 and a spaced outer side 38. The outer side 36 corresponds to the length of the half-size plastic pallet 20, while the outer side 38 corresponds to the width or end of the half-size plastic pallet 20. The length is the longer dimension of the half-size plastic pallet 20 (i.e., 40 inches), while the width is the shorter dimension of the half-size plastic pallet 20 (i.e., 24 inches).

[0047] The outer pallet support feet 40 are aligned with the outer side 38. That is, the outer side 38 is parallel to the pallet support feet 40. Each pallet support foot 40 has a length that is the same dimension as the outer side 38. That is, each pallet support foot 40 extends across the width of the half-size plastic pallet 20.

[0048] Referring now to Figures 3-6 Each pallet support foot 40 includes a base 42 and a base support assembly 52, 72 extending from the base 42. The base support assemblies 52, 72 engage to the underside 34 of the top deck 30. The base support assembly 52 can be referred to as an outer base support assembly, while the base support assembly 72 can be referred to as a center base support assembly. The outer base support assembly 52 and the center base support assembly 72 are integrally formed with the base 42.

[0049] Each outer base support assembly 52 has a lower end integrally formed with the base 42 and an exposed upper end. A pair of outward facing snaps 54 extend from the exposed upper end to contact the underside 34 of the top deck 20. Similarly, a pair of inward facing snaps 56 extend from the exposed upper end to contact the underside 34 of the top deck 20. The snaps 54, 56 are configured to engage snap openings 170 in the underside 34 of the top deck 30, causing the outer base support assembly 52 to engage to the top deck 30.

[0050] The underside 34 of the top deck 30 further has a plurality of guide openings 172 adjacent the plurality of snap openings 170. A pair of spaced guide members 58 also extend from the exposed upper end of the outer base support assembly 52. The guide members 58 are configured to align the snaps 54, 56 with the snap openings 170. The guide openings 172 correspond to the profile or outline of the outer base support assembly 52 defined by the outward facing side wall 51, the inward facing side wall 53, and the pair of curved end walls 55. The guide openings 172 in the underside 34 of the top deck 30 are smaller in dimension than the profile or outline of the outer base support assembly 52 to accommodate the guide members 58.

[0051] As Figure 10As illustrated, the snap opening 170 for the outward facing snaps 54 is outward facing, causing them to be exposed by the outer side 36 of the top deck 30, while the snap opening 170 for the inward facing snaps 56 is inward facing and not exposed. The height of the guide 58 can be the same as the height of the snaps 54, 56. In other embodiments, the height of the guide 58 can be different than the height of the snaps 54, 56.

[0052] The outer base support assembly 52 has an outward facing side wall 51 with a pair of outward facing snaps 54 extending therefrom, and a spaced apart inward facing side wall 53 with a pair of inward facing snaps 56 extending therefrom. The pair of outward facing snaps 54 is recessed from the outward facing side wall 51. The pair of inward facing snaps 56 is recessed from the inward facing side wall 53.

[0053] A pair of curved end walls 55 are at the ends of the outward facing side wall 51 and the inward facing side wall 53, and the pair of guides 58 extend from the pair of curved end walls 55. A portion of each guide 58 is curved to correspond to the curvature of the curved end walls 55. The pair of guides 58 is recessed from the pair of curved end walls 55.

[0054] Each of the snaps 54, 56 includes a flexible snap assembly 60, a lip 62 extending outwardly from the snap assembly 60, and a ramped face or edge 64 between the lip 62 and the snap assembly 60. The ramped face 64 and the lip 62 flexibly engage a corresponding snap opening 170 in the underside 34 of the top deck 30.

[0055] The central base support assembly 72 has a lower end integrally formed with the base 42, and an exposed upper end. Two pairs of outward facing snaps 74 extend from the exposed upper end to contact the underside 34 of the top deck 30. The snaps 74 are configured to engage snap openings 180 in the underside 34 of the top deck 30. As Figure 10 As illustrated, the snap openings 180 for the outward facing snaps 74 are located in the underside 34 of the top deck 30 and are not exposed by either of the outer sides 36, 38.

[0056] The underside 34 of the top deck 30 further has a plurality of guide openings 182 adjacent to the plurality of snap openings 182. Two pairs of spaced apart guides 78 also extend from the exposed upper end of the central base support assembly 72. The guides 78 are configured to align the snaps 74 with the snap openings 180 in the underside 34 of the top deck 30. The guide openings 182 correspond to the profile or outline of the central base support assembly 72 defined by the wall 73. The dimensions of the guide openings 182 in the underside 34 of the top deck 30 are less than the dimensions of the profile or outline of the central base support assembly 72 to accommodate the guides 78.

[0057] The center base support assembly 72 is circular. Two pairs of snaps 74 extend from the circular wall 73, and the guides 78 and snaps 74 are recessed from the circular wall 73. The guides 78 and snaps 74 are curved to match the curvature of the circular wall 73. The height of the guides 78 can be the same as the height of the snaps 74. In other embodiments, the height of the guides 78 can be different than the height of the snaps 74.

[0058] Each snap 74 includes a flexible snap assembly 80, a lip 82 extending outwardly from the snap assembly 80, and a beveled face or edge 84 between the lip 82 and the snap assembly 80. The beveled face 84 and the lip 82 flexibly engage a corresponding snap opening 180 in the underside 34 of the top deck 30.

[0059] The center base support assembly 72 further includes a ribbed core 90. In addition, the core 90 also extends from the exposed upper end. The height of the core 90 is less than the height of the snaps 74.

[0060] Each pallet support leg 40 is identical to one another. The base 42 in each pallet support leg 40 includes an opening 44 for receiving a reinforcing rod. The reinforcing rod increases the strength and durability of the pallet support leg 40. For example, the reinforcing rod can be, but is not limited to, steel or metal. The base 42 includes a spaced apart opening 46 that exposes the reinforcing rod. After the reinforcing rod is inserted into the opening 44, a plug 45 is inserted into the opening 44 to retain the reinforcing rod therein. For example, the opening 44 can be sized to receive a half 1 / 2 inch or 5 / 8 inch plug 45. Figure 6

[0061] Each pallet support leg 40 can be formed from a thermoplastic or polymer material. Similarly, the top deck 30 can also be formed from a thermoplastic or polymer material. The plastic used in the half size plastic pallet 20 can be recyclable.

[0062] ​Another aspect is directed to a method for manufacturing a pallet 20 having detachable pallet support feet 40 as described above. The method includes forming a top deck 30 having a product support surface 32 and an opposite underside 34, and a plurality of snap opening 170 in the underside 34. The method further includes forming a plurality of pallet support feet 40. Each pallet support foot 40 includes a base 42 extending across a width of the top deck 30, and a pair of outer base support assemblies 52. Each outer base support assembly 52 has a lower end integrally formed with an end of the base 42, and an exposed upper end. A pair of outward facing snaps 54 extend from the exposed upper end of each outer base support assembly 50 to contact the underside 34 of the top deck 30. A pair of inward facing snaps 56 extend from the exposed upper end of each outer base support assembly 50 to contact the underside 34 of the top deck 30. The method further includes engaging the pair of outward facing snaps 54 and the inward facing snaps 56 with respective snap openings 170 in the underside 34 of the top deck 30, causing the pallet support feet 40 to be joined to the top deck 30.

[0063] Reference will now be made to Figures 7-9 The top deck 30 will now be discussed in more detail. The top deck 30 is formed as one piece, and includes four quadrants 100(1)-100(4). Each quadrant can be referred to collectively as a quadrant 100. The quadrants 100 are symmetrical in design, except for the shrink wrap gripping member 110 in only quadrants 100(1) and 100(3).

[0064] The shrink wrap gripping member 110 is used to apply and hold shrink wrap on products carried by the top deck 30. Shrink wrap is often used to secure products to a pallet. This is often a replacement for strapping, but both can be applied if desired.

[0065] A problem encountered with applying shrink wrap to a pallet is securing the ends of the shrink wrap. This problem is encountered both at the beginning and at the end of the shrink wrapping, as the wrap can not adhere to the product or the pallet, or at the end, the wrap can not hold itself to the product of the pallet.

[0066] The shrink wrap gripping member 110 is positioned along the sides 36 of the top deck 30. There is one shrink wrap gripping member 110 on each side 36, i.e., on quadrants 100(1) and 100(3). In other embodiments, quadrants 100(2) and 100(4) can also include a shrink wrap gripping member 110, causing all quadrants 100 to be symmetrical in design.

[0067] Each shrink wrap gripping member 110 takes the form of a double-sided slot, similar to the shape of an anvil. The double-sided slot has a front recess and a rear recess with a narrow opening between them. The narrow opening allows the shrink wrap to be laid into the slot, but makes it more difficult to come back out. The wrap can be pulled into either the front recess or the rear recess, and the end of the wrap can be secured at the beginning or end of the wrapping process.

[0068] Another feature of the top deck 30 is the inclusion of slots 150 that serve as banding locator. A pair of slots 150 are disposed on each long side 36 of the top deck 30.

[0069] Each quadrant 100 includes a hand access hole 102. The hand access hole 102 provides an easy means for an operator to handle the half-size plastic pallet 20. The hand access hole 102 is sized large enough for a user to insert all four fingers therethrough. By providing a hand access hole 102 in each quadrant 100, a user can very easily grasp the half-size plastic pallet 20 to carry it from a stack of pallets or to unload it from a stack of pallets.

[0070] The top deck 30 includes a number of different product presenter attachment points for securing a product presenter or box to the half-size plastic pallet 20. For example, when the half-size plastic pallet 20 is located on the floor of a store with a product on it, the product presenter helps to promote the product. U.S. Patent No. 9,387,953 discloses a partial plastic pallet with product presenter attachment points, and is incorporated herein by reference in its entirety. The ’953 patent is assigned to the current assignee of the present invention.

[0071] The product presenter attachment points include presenter attachment slots 120, 130, and 150 in the product support surface 32, as Figure 9 illustrated. Each of the presenter attachment slots 120, 130, and 150 is rectangular in shape and sized to accommodate a tab that drops from the base of a product presenter, thereby holding the product presenter in place on the half-size plastic pallet 20.

[0072] With respect to all eight presenter attachment slots 120, a pair of presenter attachment slots 120 are disposed adjacent to each of the sides 36, 38 of the top deck 30. There are also eight presenter attachment slots 130 and eight presenter attachment slots 150 in the product support surface 32. Each presenter attachment slot 130 is aligned with a respective presenter attachment slot 120, and each presenter attachment slot 150 is recessed from the sides 36, 38 of the top deck 30 and also aligned with a respective presenter attachment slot 130.

[0073] Still referring to Figure 9Each display attachment slot 130 includes an outer slot 132 in the top deck 30 and an inner slot 138 recessed within the outer slot. The outer slot 132 includes sides 134 and a partially enclosed bottom 136 forming a curved shelf. The inner slot 138 is adjacent the curved shelf 136 and recessed below the outer slot 132. The inner slot 138 has a pair of spaced apart side walls 140 and 142 and an enclosed bottom 144.

[0074] Within the inner slot 132, the side wall 140 includes a protrusion 145 extending therefrom and the opposite side wall 142 includes a tapered member 146 extending therefrom. The tapered member 146 has a downward taper facing the protrusion 145. If the product display tab has a properly positioned hole, the hole can engage and lock onto the protrusion 145 or the tapered member 146.

[0075] The side wall 142 with the tapered member 146 is curved, corresponding to the curved shelf 136, while the side wall 140 with the protrusion 145 is not curved. The tapered member 146 includes a lowermost face 148 that is perpendicular to the enclosed bottom 144 of the inner slot 138. There is a gap between the flat lower side 148 and the enclosed bottom 144. For example, the protrusion 145 has a quarter-sphere shape. The tapered member 146 is aligned with the center of the protrusion 145.

[0076] Each display attachment slot 150 is recessed from the sides 36, 38 of the top deck 30. A substantial portion of the corresponding side 36, 38 of the top deck 30 is removed to expose the display attachment slot 150. The removal of the corresponding side 36, 38 of the display attachment slot 150 is uniform to form a pair of spaced apart retaining tabs 151 for securing a product display tab. The retaining tabs 151 are located at the upper portion of the display attachment slot 150, while the lower portion of the display attachment slot 150 is completely exposed.

[0077] The top deck 30 also includes openings 160, 162 for receiving reinforcing rods, as illustrated. Figure 7 The reinforcing rods increase the strength and durability of the top deck 30. For example, the reinforcing rods can be, but are not limited to, steel or metal. The side 38 has three openings 160 and the side 36 has two openings 162 for receiving the reinforcing rods. After the reinforcing rods are inserted into the openings 160, 162, a plug 45 is inserted into the openings 160, 162 to block the reinforcing rods, as shown. Figure 6 For example, the openings 160, 162 are sized to receive 1 / 2 inch or 5 / 8 inch plugs 45.

[0078] As noted above, the half-size plastic pallet 20 is repairable. The pallet support feet 40 are formed separately from the top deck 30, and for repair of the pallet, the top deck 30 can be removed from the pallet support feet 40. Each support foot 40 includes snaps 54, 56 associated with the outer base support assembly 52 and snaps 74 associated with the center base support assembly 72. The snaps 54, 56 and 74, respectively, secure each pallet support foot 40 to the underside 34 of the top deck 30.

[0079] The snaps 74 associated with the center base support assembly 72 are secured to corresponding snap openings 180 exposed from the underside 34 of the top deck 30. Similarly, the snaps 54, 56 associated with the outer base support assembly 50 are secured to corresponding snap openings 170 exposed from the underside 34 of the top deck 30. The outward facing snap pins 52 are visible from the side 36 of the top deck 30.

[0080] The product support surface 32 of the top deck 30 includes openings for receiving a jig for removing the pallet support feet 40. The jig allows contact with all of the snaps 54, 56, 74 on the pallet support feet 40 to un-snap them from the underside 34 of the top deck 30.

[0081] Reference is now made to Figures 10-12 The four approximately symmetrical quadrants 100 will be discussed in more detail. Each quadrant 100 includes a pair of spherical carvings 200, 210. The spherical carvings 200, 210 can also be referred to as deck scoop areas. The spherical carvings 200, 210 each reduce the thickness of the top deck 30 within each quadrant 100. Advantageously, the spherical carvings 200, 210 reduce the impact of the center quadrant flexing on the ability of the tines of the fork to pass through the opening under the top deck 30. Center quadrant flexing can occur when the load on the half-size plastic pallet 20 is heavy.

[0082] In other embodiments, each quadrant 100 can include a single spherical carving, such as the spherical carving 200 or 210. In yet other embodiments, the single spherical carving can partially overlap between the spherical carvings 200 or 210.

[0083] The spherical carving 200 can be referred to as a first deck scoop area, and the spherical carving 210 can be referred to as a second deck scoop area. The second deck scoop area is larger in size than the first deck scoop area 200. The first deck scoop area 200 has a rectangular shape, and the second deck scoop area 210 has a square shape.

[0084] The underside 34 of the top deck 30 is made of exposed ribs. The first deck well 200 includes a respective hand access hole 102. The hand access hole 102 is located in the center of the first deck well 200. The hand access hole 102 is located at the apex of a curved portion within the first deck well 200. This apex corresponds to the point of minimum thickness of the top deck 30 within the first deck well 200.

[0085] The hand access hole 102 includes a wall 103 that extends from the product support surface 32 to the opposing underside 34 of the top deck 30. Within the first deck well 200, exposed ribs 202 extend in a first direction, while exposed ribs 204 extend in a second direction that is orthogonal to the first direction.

[0086] The first deck well 200 in each quadrant 100 is adjacent to the outer side 38 of the top deck 30. The quadrant 100 has a uniform thickness between the outer side 38 and the first deck well 200 at an outer perimeter region 215 that is not part of the first deck well 200. The outer perimeter region 215 of the quadrant 100 extends around the perimeter of the top deck 30 for all four quadrants. The perimeter region is adjacent to the outer sides 35 and 38.

[0087] A transition wall 220 separates the second deck well 210 from the first spherical wedge head 200. The thickness of the top deck 30 does not decrease at the transition wall 220. The ribs within the second deck well 210 include ribs 212 that extend in a first direction and ribs 214 that extend in a second direction that is orthogonal to the first direction.

[0088] In each quadrant 100, the second deck well 210 includes a plurality of spaced apart openings 230, as Figure 8 illustrated. The openings 230 extend to the underside 34 of the top deck 30. The openings 230 can be divided into spaced apart opening segments that are laid out in a grid pattern. Within each second deck well 210, each opening segment has a pattern of openings 230 that is symmetrical to each of the other opening segments.

[0089] Another aspect is directed to a method of manufacturing a pallet 20 having deck wells 200, 210 as described above. The method includes forming a top deck 30 that is divided into quadrants 100 and forming a plurality of pallet support feet 40. The pallet support feet 40 are joined to the underside 34 of the top deck 30 and form openings underneath the top deck 30 for receiving lifting members. The top deck 30 is formed to include at least one deck well 200, 210 on the underside 34 thereof in each quadrant 100. The thickness of the top deck 30 is decreased in each deck well 200, 210 to reduce the effect of top deck deflection on the ability of the lifting members to pass through the openings underneath the top deck 30.

[0090] The top deck 30 can be further configured to accommodate the attachment of an electronic tracking device. For example, a compartment can be formed or attached to the underside 34 of the top deck 30 to carry the electronic tracking device. Fasteners can be used for attachment, including screws or other hardware, plastic clips, or combinations thereof. The electronic tracking device can be configured to store data during use of the pallet. The electronic tracking device can include, but is not limited to, communication protocols such as Bluetooth, Bluetooth Low Energy (BLE), RFID, cellular, and GPS.

[0091] Referring now to Figures 13-21 , the use of grommets 250 within the top deck 30 is discussed. Advantageously, the grommets 120 provide better grip when an item is placed on the product support surface 32 of the top deck 30, and on the underside 34 of the top deck 30, with the tines of a fork lift. Advantageously, the grommets 250 also assist in positioning the same half-size plastic pallet 20, for example, when stacked on another half-size plastic pallet 20. Suitable materials for the grommets 250 include, for example, natural and synthetic rubbers.

[0092] Each quadrant 100 has a pair of grommets 250. One of the grommets 250 is in the outer perimeter region 215 of the top deck 30. The other grommet 250 is within the second deck pocket region 210 and is orthogonal to the grommet 250 in the outer perimeter region 215. In the illustrated embodiment, there are eight grommets 250. Those skilled in the art will readily appreciate that the number, location, and size of the grommets 250 can vary.

[0093] Each grommet 250 is inserted through a rectangular grommet opening 270 that extends through the top deck 30, as illustrated. Figure 15 The grommet opening 270 is recessed from the upper surface 32 of the top deck 30 to form a recess 272. The grommet opening 270 has a first perimeter dimension above the recess 272.

[0094] Below the recess, the opening 270 has a second perimeter dimension that is smaller than the first perimeter dimension. Included within the second perimeter dimension is a divider 274. The upper surface of the divider 274 is recessed from the recess 272, and the lower surface of the divider 272 extends to the underside 34 of the top deck 30. The divider 274 requires that the lower portion of each grommet 250 have a slit or gap 259 to accommodate the divider 274.

[0095] Each grommet 250 includes an upper section 253 that includes an upper lip 252 that engages or rests on the recess 272. The upper surface 254 of each grommet 250 is flat and elevated above the product support surface 32 of the top deck 30. The transition zone 256 between the upper surface 354 and the upper lip 252 of each corresponding grommet 250 is curved.

[0096] A pair of mid-sections 258 extend from the upper section 253 of each grommet 250. The mid-sections 258 are located on adjacent sides of the divider 274. A respective lower section 260 extends from each mid-section 258. The lower sections 260 extend through to the underside 34 of the top deck 30 and are flared for engaging the underside 34 of the top deck 30, as Figure 9 illustrated. Each lower section 260 includes a lower lip 263 that engages or rests on the underside 34 of the top deck 30.

[0097] In addition to the grommets 250, the product support surface 32 of the top deck 30 includes an array of friction points 290 to prevent products from sliding on the product support surface 32, as Figure 19 illustrated. For example, each friction point 290 has a circular shape and is in the form of a raised stub. To reduce the weight and amount of material needed to form the half-size plastic pallet 20, the top deck 30 and the pallet support feet 40 include a number of spaced apart openings 230, as discussed above.

[0098] Another aspect is directed to a method of manufacturing a pallet 20 having grommets 250 as described above. The method includes forming a top deck 30 having a plurality of grommet openings 270 extending therethrough and each grommet opening 270 includes a recess 272. A plurality of grommets 250 are inserted into the plurality of grommet openings 270. Each grommet 250 includes an upper section 253 that includes an upper lip 252 that rests on the recess 272 and an exposed face 254 of the upper section 253 extends above the top deck 30 in height. At least one mid-section 258 is adjacent to the upper lip 252 and extends from the upper section 253 to the underside 34 of the top deck 30. At least one lower section 260 extends from the at least one mid-section 258 and includes a pair of spaced apart lower lips 263 that rest on the underside 34 of the top deck 30. An exposed face 264 of the at least one lower section 260 extends below the underside 34 of the top deck 30 in height. The method further includes forming a plurality of pallet support feet 40 and engaging the plurality of pallet support feet 40 to the underside 34 of the top deck 30 and forming an opening in the underside of the top deck 30 for receiving a lifting member.

[0099] Reference is now made to Figure 22 and 23adjacent the outer side 38 of the top deck 30 facilitate the retention of the stacked half-size plastic pallets 20 in place. This is accomplished with the upper surface 254 of the grommet 250 being elevated above the upper product support surface 32 of the top deck 30. For example, the elevated upper surface 254 of the grommet 250 above the product support surface 32 of the top deck 30 can be in the range of 0.25 to 0.75 inches. This range is not limiting as the actual elevated upper surface 254 can vary outside of this range.

[0100] A pair of corresponding openings 300 are located in the underside of the pallet support foot 40 for engagement with the upper surface 254 of the grommet 250 of a stacked pallet 20, as Figure 23 illustrated by the cross-sectional view of a stacked half-size plastic pallet 20 in FIG. 3. Each opening 300 is sized to accommodate the upper section 253 of the grommet 250, including the upper surface 254 and a portion of the transition region 256 between the upper surface 254 and the upper lip 252.

[0101] In particular, the pallet 20 includes a top deck 30 that includes a product support surface 32 and an opposite underside 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes a recessed grid 272.

[0102] A plurality of grommets 250 are inserted into the plurality of grommet openings 270. Each grommet 250 includes an upper section 253 that includes an upper lip 252 that rests on the recessed grid 272, and an exposed face 254 of the upper section 253 extends in height above the upper surface of the top deck 30.

[0103] A plurality of pallet support feet 40 are located on the underside 34 of the top deck and are aligned with the plurality of grommets 250 adjacent the outer side 38 of the top deck 30. Each pallet support foot 40 includes a base 42 that extends across the width of the top deck 30, and a pair of outer base support assemblies 52. Each outer base support assembly 52 has a lower end that is integrally formed with an end of the base 42, and an upper end that engages the underside 34 of the top deck 30. The underside of the base 42 is configured to engage the upper section 253 of a pair of grommets 250 of the same pallet 20 when stacked thereon.

[0104] The underside 34 of the base 42 includes a plurality of grommet openings 300, as Figure 5 illustrated in FIG. 4. Each grommet opening 300 is configured to accommodate the upper section 253 of a respective grommet 250 of the same pallet 20 when stacked thereon. There are four grommet openings 300 in the base 42, such that the outer pallet support foot 40 can engage to the top deck 30 without being limited to an adjacent arrangement with a particular outer side 38 of the top deck 30.

[0105] The upper section 253 of each grommet 250 includes an upper surface 254, and the transition 256 between the upper surface 254 and the upper lip 252 is curved. The curved transition 256 acts as a guide to seat the upper surface 254 of the upper section 253 of the grommet 250 in the corresponding opening 300 in the base 42 of the deck support foot 40. A plurality of grommet openings 270 are seated at the opposite lateral sides 38 of the top deck 30, and each opposite lateral side 38 has a pair of spaced apart grommet openings 270.

[0106] Another aspect is directed to manufacturing a deck 20 that can be stacked with other identical decks 20 as described above. The method includes forming a top deck 30 that includes a product support surface 32 and an opposite lower side 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes a recess 272.

[0107] The method further includes inserting a plurality of grommets 250 into the plurality of grommet openings 270. Each grommet 250 includes an upper section 253 that includes an upper lip 252 that rests on the recess 272. The exposed surface 254 of the upper section 253 extends in height above the top deck 30.

[0108] The method further includes forming a plurality of deck support feet 40. Each deck support foot 40 includes a base 42 that extends across the width of the top deck 30, and a pair of outer base support assemblies 52. Each outer base support assembly 52 has a lower end that is integrally formed with an end of the base 42, and an upper end that engages the lower side 34 of the top deck 30. The lower side of the base 42 is configured to engage the upper sections 253 of a pair of grommets 250 of an identical deck 20 when stacked thereon. The plurality of support feet 40 engage the lower side 34 of the top deck 30, and the plurality of support feet 40 are aligned with the plurality of grommets 250.

[0109] Another feature of the top deck 30 is that it can be reconfigured into a deck / pallet platform 30. By adding pallet wheels 402 to the reconfigurable deck / pallet platform 30, a pallet 400 is formed as Figures 24-29 illustrated. Advantageously, the reconfigurable deck / pallet platform 30 is reconfigured to support a half-size plastic deck 20 or a half-size pallet 400.

[0110] When the reconfigurable deck / pallet platform 30 is configured as a pallet 400, the deck support feet 40 are not engaged to the lower side 34 of the platform 30. Also, when the reconfigurable deck / pallet platform 30 is configured as a deck 20, the pallet wheels 402 are not engaged to the lower side 34 of the platform 30.

[0111] Referring back to the illustration of the lower side 34 of the top deck 30,Figure 11 When configured as a cradle 400, a plurality of cradle wheel attachment areas 410 are provided for receiving a plurality of cradle wheels 402. There are six cradle wheels 402 attached to the underside 34 of the top deck 30 and three on each side 36. Each cradle wheel attachment area 410 includes four attachment points 412 for securing the cradle wheels 402. When the top deck 30 is used as a pallet, additional attachment points can be provided to accommodate a cover.

[0112] In the product support surface 32 of the reconfigurable pallet / cradle platform 30, a plurality of cradle wheel pockets 420 are provided. The plurality of cradle wheel pockets 420 are aligned with the plurality of cradle wheel receiving areas 410. Each cradle wheel pocket 420 is configured to engage a respective cradle wheel 402 of the same cradle 400 stacked thereon. By having the cradle wheel pockets 420 receive the cradle wheels 402 of the stacked cradle 400, stability is provided when the stacked cradle 400 is moved.

[0113] In addition, each cradle wheel pocket 420 can include a drainage opening to cause water or other liquids to not accumulate. The cradle wheels 402 located at one end of the cradle 400 can rotate about an axis perpendicular to the top deck 30, while the other four cradle wheels 402 do not rotate.

[0114] In particular, the reconfigurable pallet / cradle platform 30 includes a top deck 30 that includes a product support surface 32 and opposing sides 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough and each grommet opening 270 includes a recess 272.

[0115] When configured as a pallet 20, the underside 34 includes a plurality of pallet support foot attachment areas 430, 432 that are aligned with the plurality of grommet openings 270 and are for receiving a plurality of pallet support feet 40. When configured as a cradle 400, the plurality of cradle wheel attachment areas 410 are for receiving a plurality of cradle wheels 402.

[0116] The product support surface 32 includes a plurality of grommets 270 inserted into the plurality of grommet openings 250. Each grommet 270 includes an upper section 253 that includes an upper lip 252 that rests on the recess 272. When configured as a pallet 20, the exposed face 254 of the upper section 253 extends in height above the upper face of the top deck and is configured to engage the underside 300 of the pallet support feet 40 of the same platform 30 stacked thereon.

[0117] When configured as a cradle 400, the plurality of cradle wheel receiving areas 410 are aligned with the plurality of cradle wheel pockets 420 and are configured to engage the plurality of cradle wheels 402 of the same platform 30 stacked thereon.

[0118] The underside of each pallet support foot 40 includes a plurality of grommet openings 300, and each grommet opening 300 is configured to receive an upper section 254 of a respective grommet 250 of the same pallet 20 when stacked thereon.

[0119] Another aspect is directed to manufacturing a reconfigurable pallet / platform 30, which includes forming a top deck 30 including a product support surface 32 and an opposing underside 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes a recess 272.

[0120] When configured as a pallet 20, the underside 34 includes a plurality of pallet support foot attachment regions 430, 432 that are aligned with the plurality of grommet openings 270 and configured to receive a plurality of pallet support feet 40. When configured as a carrier 400, the plurality of carrier wheel attachment regions 410 are configured to receive a plurality of carrier wheels 402.

[0121] The product support surface 32 includes a plurality of grommets 270 inserted into the plurality of grommet openings 250. Each grommet 270 includes an upper section 253 that includes an upper lip 252 that rests on the recess 272. When configured as a pallet 20, the exposed face 254 of the upper section 253 extends in height above the top deck and is configured to engage the underside 300 of a pallet support foot 40 of the same platform 30 stacked thereon.

[0122] When configured as a carrier 400, the plurality of carrier wheel receiving regions 410 are aligned with the plurality of carrier wheel pockets 420 and are configured to engage the plurality of carrier wheels 402 of the same platform 30 stacked thereon.

[0123] Many modifications and other embodiments will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

Claims

1. A pallet, comprising: The top deck is divided into four sections; as well as Multiple pallet support feet, the multiple pallet support feet engaging the underside of the top deck and forming an opening under the top deck for accommodating a lifting member, and the opening having a length between the individual pallet support feet of the multiple pallet support feet; The top deck includes at least two deck bucket sections in each of its lower sections, and one of the at least two deck bucket sections is longer than the other of the at least two deck bucket sections. The thickness of the top deck has a curved portion in each deck bucket section to reduce the effect of top deck deflection on the ability of the lifting member to pass through the opening below the top deck.

2. The pallet according to claim 1, wherein one of the at least two deck compartments in each quarter includes a hand grip opening.

3. The pallet according to claim 1, wherein each quarter includes a respective transition wall that separates each of the at least two deck bucket areas, and the transition wall does not reduce the thickness of the top deck.

4. The pallet of claim 1, wherein the underside of the deck includes exposed ribs, and the at least two deck sections in each quarter include the exposed ribs.

5. The pallet according to claim 1, wherein the top deck includes an outer peripheral region surrounding the at least two deck bucket areas, and the thickness of the top deck does not decrease in the outer peripheral region.

6. The pallet according to claim 1, wherein one of the at least two deck bucket areas in each quarter has a rectangular shape.

7. The pallet of claim 1, wherein the top deck has a product support surface, and the product support surface includes a plurality of openings extending to the lower side, and the openings form a grid pattern in the at least two deck bucket areas in each quarter, and each grid pattern is symmetrical to the grid patterns in the other quarters.

8. The pallet of claim 1, wherein the top deck and each pallet support foot comprise plastic.

9. A pallet, comprising: The top deck is divided into four sections, and each section includes at least two deck buckets on its underside, and the thickness of the top deck has a curved portion in each deck bucket. as well as A plurality of pallet support feet are coupled to the underside of the top deck and form an opening in the underside of the top deck, the opening having a length between each of the plurality of pallet support feet. The length of one of the at least two deck bucket areas is greater than the length of the other of the at least two deck bucket areas.

10. The pallet of claim 9, wherein one of the at least two deck compartments in each of the quarters includes a hand grip opening.

11. The pallet of claim 9, wherein the at least two deck sections in each quarter are spaced apart from each other.

12. The pallet of claim 11, wherein each quarter comprises a respective transition wall that separates each of the two deck bucket areas, and the transition wall does not reduce the thickness of the top deck.

13. The pallet of claim 9, wherein the underside of the deck includes exposed ribs, and one of the at least two deck bucket areas in each quarter includes the exposed ribs.

14. The pallet of claim 9, wherein the top deck includes an outer peripheral region that surrounds the at least two deck bucket areas in each of the quarters, and the thickness of the top deck does not decrease in the outer peripheral region.

15. The pallet of claim 9, wherein one of the at least two deck sections in each quarter has a rectangular shape.

16. The pallet of claim 9, wherein the top deck comprises plastic.

17. A method for manufacturing a pallet, comprising: This forms a top deck that is divided into four sections; Multiple support feet are formed for the tray; The plurality of pallet support feet are engaged to the underside of the top deck, forming an opening under the top deck for accommodating a lifting member, and the opening having a length between the respective pallet support feet of the plurality of pallet support feet; as well as The top deck is formed by forming at least two deck bucket sections in each of its lower sides, wherein the length of one of the at least two deck bucket sections is greater than the length of the other of the at least two deck bucket sections, and the thickness of the top deck has a curved portion in each deck bucket section to reduce the effect of top deck deflection on the ability of the lifting member to pass through the opening between the sections below the top deck.

18. The method of claim 17, wherein one of the at least two deck bucket areas in each quadrant includes a hand grip opening.

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