Pallet with centerline marking and method of making same

Abstract

A pallet includes: a top deck having a rectangular shape and four externally exposed edges; a bottom deck having a rectangular shape and four externally exposed edges; a plurality of spaced apart corner support blocks and a plurality of intermediate support blocks, the plurality of spaced apart corner support blocks and the plurality of intermediate support blocks being coupled between the top deck and the bottom deck and forming a plurality of respective gaps therebetween and along the four externally exposed edges of the top deck and the bottom deck, the four outer exposed edges are used for receiving a lifting component through any one of the four outer exposed edges; and a plurality of centerline indicia between the plurality of corner support blocks and the plurality of intermediate support blocks on at least two of the four externally exposed edges on each side of the top deck and the bottom deck to provide forward facing visual assistance to an operator of the lifting member.

Description

[0001] This application is a divisional application based on the patent application of the applicant CHEP Technology Co., Ltd., whose application date is October 13, 2017, application number is CN2017800719755 (international application number is PCT / US2017 / 056479) and invention name is "Plastic pallet with centerline marking and method thereof". Technical Field

[0002] The present invention relates to the field of pallets, and more particularly to a plastic pallet used with forklift equipment and a manufacturing method thereof. Background Art

[0003] Pallets are traditionally used for transporting and storing goods. Pallets typically include a top deck and a bottom deck separated by support blocks. Pallets are traditionally made of wood. Although advantageous in terms of cost, wood pallets have many disadvantages. For example, they are prone to breaking and can therefore only be reused for a short period of time. Wooden pallets are also difficult to maintain in clean conditions, thereby limiting their usefulness in applications where cleanliness is important, such as in food processing applications.

[0004] As the plastics industry has grown, a wide variety of plastics have been investigated to determine their suitability for use in the production of pallets. Plastic pallets can be easily molded and are stronger and lighter than wooden pallets. They can also be made from recyclable materials.

[0005] Plastic pallets are generally more durable than wooden pallets. Nevertheless, the support blocks that separate the top and bottom decks are subject to the most severe wear of any part of the pallet because of their repeated contact with the sharp metal teeth of the forklift or pallet jack.

[0006] Furthermore, if the teeth of the pallet jack are inserted too far between the top and bottom decks so that the wheels of the pallet jack rest on the bottom deck, the top deck may become separated from the bottom deck when the teeth are lifted. The damage caused by the separation of the top deck from the bottom deck requires replacement of the top deck and, if the damage is too great, replacement of the entire pallet.

[0007] If only the support blocks are damaged by the pallet jack, they can be replaced at a cost far less than replacing the entire pallet. For example, U.S. Patent No. 5,413,052 discloses a plastic pallet having a top deck and a bottom deck with replaceable support blocks therebetween. The support blocks include octagonal posts having support member walls disposed below a reinforced portion of the top deck. The posts also have sleeves having central bolt holes parallel to the support member walls. The bottom deck receives the support blocks in recessed pockets. Plastic bolts are inserted through the top deck, each post and the bottom deck. Plastic T-nuts are used to hold the bolts in place.

[0008] In U.S. Pat. No. 4,843,976, a plastic pallet comprises identical top and bottom decks interconnected by support blocks. Each support block comprises a central core and surrounding sleeves interconnected by spokes. The core has flexible protrusions that extend through opposite ends of the sleeves and lock onto the top and bottom decks.

[0009] The plastic pallet disclosed in U.S. Patent No. 5,791,261 also discloses the use of flexible protrusions for holding the top and bottom decks together. Specifically, the plastic pallet includes a support block between the top and bottom decks, and upper and lower spring lock assemblies extend from the respective top and bottom decks through the support block for interlocking with each other.

[0010] While plastic pallets offer several advantages over wood pallets, there remains a need to increase the durability and strength of plastic pallets. Summary of the invention

[0011] According to a first aspect of the present invention, there is provided a pallet, which comprises: a top deck having a rectangular shape and four externally exposed edges; a bottom deck having a rectangular shape and four externally exposed edges; a plurality of spaced-apart corner support blocks and a plurality of intermediate support blocks, wherein the plurality of spaced-apart corner support blocks and the plurality of intermediate support blocks are coupled between the top deck and the bottom deck and form a plurality of corresponding gaps between them and along the four externally exposed edges of the top deck and the bottom deck for receiving a lifting member through any one of the four externally exposed edges; and a plurality of spaced-apart corner support blocks and the plurality of intermediate support blocks between the top deck and the bottom deck. A plurality of centerline markings on at least two of the four exterior exposed edges on each side of the bottom deck to provide a forward-facing visual aid to an operator of the lifting member to position the lifting member in two of the plurality of gaps, each centerline marking on the exterior exposed edges of the top deck and the bottom deck having a broken line in the centerline marking to indicate the center of the corresponding gap between the corner support block and the middle support block, and each centerline marking comprises pre-molded plastic having a first color surrounded by molded plastic having a second color, the first color being lighter than the second color.

[0012] According to a second aspect of the present invention, a method for manufacturing a pallet is provided, the method comprising: forming a top deck having a rectangular shape and an externally exposed edge; forming a bottom deck having a rectangular shape and an externally exposed edge; coupling a plurality of spaced-apart corner support blocks and a plurality of intermediate support blocks, the plurality of spaced-apart corner support blocks and the plurality of intermediate support blocks being coupled between the top deck and the bottom deck and forming a gap therebetween for receiving a lifting member; and providing a plurality of centerline markings on the externally exposed edge on each side of the top deck and the bottom deck between the plurality of corner support blocks and the plurality of intermediate support blocks to provide a visual aid to an operator of the lifting member, each centerline marking on the externally exposed edge of the top deck and the bottom deck having a broken line in the centerline marking to indicate the center of the gap between the corner support block and the intermediate support block, and each centerline marking comprising a pre-molded plastic having a first color surrounded by molded plastic having a second color, the first color being lighter than the second color. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a perspective view of a plastic pallet having a support block with a pocket for pin rotation according to the present invention.

[0014] Figure 2 yes Figure 1 An enlarged perspective view of the corner support block shown in FIG.

[0015] Figure 3 yes Figure 1 An enlarged perspective view of the intermediate support block shown in FIG.

[0016] Figure 4-6 yes Figure 1 Perspective views of different embodiments of corner support blocks are shown in FIG.

[0017] Figure 7 yes Figure 1 An enlarged perspective view of a corner of the bottom deck is shown in FIG.

[0018] Figure 8 yes Figure 1 An enlarged perspective view of the corner support block shown in FIG.

[0019] Fig. 9 yes Figure 1 A perspective view of the plastic pallet shown in , with the centerline marked.

[0020] Fig.10 yes Figure 1 An upper perspective view of a corner support block shown in FIG. 1 with an upper tower extending therefrom.

[0021] Fig.11yes Figure 1 An enlarged perspective view of a corner of a top deck shown in FIG. 1 with an upper tower opening therein.

[0022] Fig.12 yes Figure 1 A lower perspective view of a corner support block shown in FIG. 4 having a pair of protrusions extending therefrom.

[0023] Fig.13 yes Figure 1 An enlarged perspective view of a corner of a bottom deck shown in FIG. 4 having a pair of raised openings therein.

[0024] Fig.14 yes Figure 1 An enlarged perspective view of the underside of the plastic pallet shown in FIG.

[0025] Fig.15 yes Figure 1 A perspective view of a snap pin used in a plastic pallet is shown.

[0026] Fig.16 yes Figure 1 A partially cut-away perspective view of a plastic pallet shown in , having a tubular insert in the top deck.

[0027] Fig.17 yes Figure 1 A cross-sectional view of the corner of a plastic pallet shown in , exposing a tubular insert in the top deck.

[0028] Fig.18 yes Figure 1 An exploded view of another embodiment of a support block is shown in FIG. 1 , having inner and outer blocks.

[0029] Fig.19 yes Fig.18 An upper perspective view of a support block shown in FIG. 5 having upper and lower blocks joined together.

[0030] Fig. 20 yes Fig.18 A lower perspective view of a support block shown in FIG. 5 having upper and lower blocks joined together.

[0031] Fig.21 yes Figure 1 An upper perspective view of another embodiment of a support block shown in FIG. 4 having an upper tower and a lower tower.

[0032] Fig. 22 yes Fig.21 A cross-sectional view of a pallet with support blocks is shown in FIG.

[0033] Fig.23 yes Fig. 22A perspective view of a corner of a pallet shown in FIG. 1 without support blocks to illustrate the interlocking tower assemblies extending through the support blocks.

[0034] Fig.24 yes Fig. 22 A cross-sectional view of the interlocking tower assembly shown in FIG. 1 is shown fully in place.

[0035] Figure 25-27 yes Fig. 22 sectional views of the interlocking tower assembly shown in FIG. 1 at various stages of not being fully seated. DETAILED DESCRIPTION

[0036] The present invention will now be more fully described herein and below with reference to the accompanying drawings, in which preferred embodiments are shown. However, the present invention can be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to make this disclosure thorough and complete and to fully convey the scope of the invention to those skilled in the art. The same numbers always refer to the same elements.

[0037] See first Figure 1-2 The plastic pallet 20 includes a top deck 30 having a rectangular shape, a bottom deck 40 having a rectangular shape, and a plurality of spaced-apart corner support blocks 50 coupled between corners of the top and bottom decks and forming gaps therebetween to receive a lifting member. The lifting member may be a metal tooth portion of a forklift or a pallet jack. The top deck 30 is also referred to as a cargo layer, and the bottom deck 40 is also referred to as a base layer. The plastic pallet 20 also includes a middle support block 80 coupled between middle regions of the top and bottom decks 30, 40.

[0038] Each corner support block 50 includes a pair of exposed support block side surfaces 52, 54 that align with respective corners of the pallet 20. Each exposed support block side surface 52, 54 has a pocket 60 formed therein for receiving an end of a lifting member to allow the pallet 20 to be turned when on the ground.

[0039] The remaining exposed support block side surfaces of each corner support block 50 also have respective pockets 60 formed therein. As a result, the exposed sides of each corner support block 50 are symmetrical with respect to their opposite sides. In the illustrated embodiment, each corner support block 50 is rectangular in shape, wherein the length of the exposed support block side surface 54 is longer than the length of the other exposed support block side surface 52. In other embodiments, the lengths of the exposed support block side surfaces 52, 54 are equal, such that the corner support block 50 is square in shape.

[0040] For example, a plastic pallet 20 may have dimensions of 40 inches by 48 inches. Sometimes, the load on the pallet 20 may overhang the sides of the pallet. For example, when such pallets 20 are loaded onto a 96-inch wide trailer, some pallets 20 will need to be turned or rotated 90 degrees by a forklift operator so that two pallets can fit side by side.

[0041] Rotating the pallet 20 by the forklift operator is called pin wheeling. To pin wheel a pallet 20, the forklift operator uses one of the forklift's sharp metal teeth to contact one of the pockets 60 of the exposed side surface of the corner support block 50. The pocket 60 advantageously allows the tooth to grip the pallet to allow it to be rotated 90 degrees. Without the pocket, the tooth could dig into one of the exposed support block side surfaces 52, 54, causing damage to the corner support block 50.

[0042] Each pocket 60 is recessed from respective adjacent outer edges 32, 34 of the top deck 30 and respective adjacent outer edges 42, 44 of the bottom deck 40. The exposed support block side surfaces 52, 54 of each corner support block 50 having a pocket 60 formed therein include an outer exposed wall 62 surrounding the pocket. The pocket 60 includes a bottom surface 64 and an adjacent side surface 66, and the adjacent side surface is non-orthogonal or beveled relative to the outer exposed wall 62 and the bottom surface. Alternatively, the adjacent side surface 66 can be orthogonal or perpendicular relative to the outer exposed wall 62 and the bottom surface 64.

[0043] Each corner support block 50 includes an exposed support block corner surface 70 extending between a pair of exposed support block side surfaces 52, 54. Each corner support block 50 thus has an octagonal shape. The exposed support block corner surface 70 can be straight or rounded to match the corresponding exposed corner surfaces 35, 45 in the top and bottom decks 30, 40.

[0044] Similarly, each intermediate support block 80 includes a plurality of exposed support block side surfaces 82, each of which has a pocket 90 formed therein, such as Figure 3 One of the exposed support block side surfaces 82 is aligned with the outer edges 32 , 34 of the top and bottom decks 30 , 40 .

[0045] Each intermediate support block 80 also includes exposed support block corner surfaces 86 extending between any two adjacent pairs of exposed support block side surfaces 82. The pockets 90 in the intermediate support blocks 80 are similar to the pockets 60 in the corner support blocks 50.

[0046] The corner and intermediate support blocks 50, 80 with pockets 60, 90 for pin rotation are not limited to Figure 1-3 The embodiment shown in . Figure 4106, is defined by a single post 102 aligned with the corner of the pallet, and upper and lower ledges 104 and 106 extending from each side of the single post around the perimeter of the corner support block 100. An exposed support block side surface 108 extending between the upper and lower ledges 104, 106 forms a pocket 110. The transition between the single post 102 and the exposed support block side surface 108 and the upper and lower ledges 104, 106 is curved. Referring now to FIG. Figure 5 The corner support block 120 is defined by four posts 122 together with an exposed support block side surface 124 extending between any two adjacent posts. One of the posts 122 is aligned with the corner of the pallet. Each exposed support block side surface 124 forms a pocket 130 relative to its adjacent posts 122. The transition between each post 122 and the exposed support block side surface 124 is curved.

[0047] In yet another embodiment, each corner support block 140 is defined by four posts 142 together with an exposed support block side surface 144 extending between any two adjacent posts, such as Figure 6 As shown. Each exposed support block side surface 144 forms a pocket 150 relative to its adjacent column 142. In this embodiment, the corner support block 140 is positioned so that the pocket 150 is aligned with the corner of the pallet. In addition, the corner support block 140 is square so that the transition between each column 142 and the exposed support block side surface 144 is significantly curved.

[0048] Reference now Figure 2 , 7 8, another aspect of the pallet 20 is directed to each corner support block 50 having a corner guard or stop tooth 170 to protect the corners of the bottom deck 40 from impact by the teeth of a forklift or pallet jack.

[0049] As described above, each corner of the bottom deck 40 has a pair of exposed bottom deck side surfaces 42 , 44 , and an exposed bottom deck corner surface 45 extending between the pair of exposed bottom deck side surfaces.

[0050] Each exposed support block side surface 52, 54 aligned with the respective corner has a lower end region 150 and a lower end middle region 152 extending between the lower end regions. The lower end middle region 152 is recessed relative to the lower end region 150. The exposed support block corner surface 70 extending between a pair of exposed support block side surfaces 52, 54 has a lower end corner region 172 aligned with the lower end region 150 in the adjacent exposed support block side surfaces 52, 54 to protect the corner of the bottom deck 40.

[0051] The bottom deck 40 also includes a pair of raised outer ridges 162 adjacent each corner. Each raised outer ridge 162 contacts a corresponding lower intermediate region 152 of the exposed support block side surfaces 52, 54. One of the exposed bottom deck side surfaces 42 adjacent each corner includes an inner backstop 172 that contacts the interior of one of the exposed support block side surfaces 52. If the corner support block 50 is struck by a forklift on the exposed support block side surfaces 52 over time, the inner backstop 172 helps absorb some of the impact. The inner backstop 172 is located on the short sides of the corner support block 50.

[0052] Portions 182 , 184 , 185 of the exposed bottom deck side surfaces 42 , 44 and the exposed bottom deck corner surface 45 , respectively, are inclined or beveled relative to the bottom surface of the bottom deck.

[0053] Another aspect is directed to a method for manufacturing a pallet 20 having a pocket 60 as described above. The method includes forming a top deck 30 having a rectangular shape, forming a bottom deck 40 having a rectangular shape, and forming a plurality of spaced-apart corner support blocks 50 coupled between the corners of the top and bottom decks and forming gaps therebetween for receiving a lifting member. Each corner support block 50 includes a pair of exposed support block side surfaces 52, 54 aligned with respective corners, and each exposed support block side surface has a pocket 60 formed therein for receiving an end of a lifting member to allow the pallet to be turned.

[0054] Now refer to Fig. 9 Discussing a plastic pallet 20 having centerline markings 180, 182, 184. The centerline markings 180, 182, 184 advantageously provide a visual aid to a forklift operator, for example, to more easily see the gap or opening between the top and bottom decks 30, 40 of the plastic pallet 20. Thus, the visual aid on the plastic pallet 20 helps reduce forklift tooth impacts.

[0055] The pallet 20 includes a top deck 30 having a rectangular shape with exposed outer edges 32, 34, and a bottom deck 40 having a rectangular shape with exposed outer edges 42, 44. Spaced-apart corner support blocks 50 are coupled between the corners of the top and bottom decks 30, 40 and form a gap therebetween. The plastic pallet 20 also includes a middle support block 80 coupled between the middle regions of the top and bottom decks 30, 40.

[0056] In the illustrated embodiment, the top deck 30 has a centerline marking 180, the bottom deck 40 has a centerline marking 182, and each corner support block 50 has a centerline marking 184. Additionally, each intermediate support block 80 has a centerline marking 186.

[0057] In other embodiments, the plastic pallet 20 may include one or any combination of centerline markings 180, 182, 184, 186, as will be readily understood by one skilled in the art. For example, the centerline markings 184, 186 are on the middle and corner support blocks 80, 50, but not on the top and bottom decks 30, 40. Alternatively, as another example, the centerline markings 180, 182 are on the top and bottom decks 30, 40, but not on the middle and corner support blocks 80, 50.

[0058] The centerline markers 180-186 preferably include a reflective and durable material. The centerline markers 180-186 can be applied in a variety of different ways. For example, the centerline markers 180-186 can be painted, they can be pad printed, or they can be in the form of tape or stickers. In some applications, the surface of the pallet 20 that receives the centerline markers 180-186 is recessed to increase durability. The centerline markers 180-186 can also be applied in an in-line molding process. The centerline markers 180-186 are pre-molded with a lighter color plastic. Then, when the top and bottom decks 30, 40 and the middle and corner support blocks 80, 50 are formed with a darker color plastic, the pre-molded centerline markers 180-186 are placed in separate molds. The darker color plastic contrasts with the lighter color plastic of the pre-molded centerline markers 180-186.

[0059] In the illustrated embodiment of the top deck 30, the exposed outer edges 32, 34 have centerline markings 180. Similarly, the exposed outer edges 42, 44 of the bottom deck 40 have centerline markings 182. As shown, respective centerline markings extend between each corner support block 50 and intermediate support block 80. Also as shown, there are gaps or breaks in the centerline markings 180, 182 to indicate the center of the gaps between adjacent corner support blocks 50 and intermediate support blocks 80.

[0060] Alternatively, the centerline markings 180 , 182 may be continuous so as not to include such gaps. In addition, the centerline markings 180 , 182 may be continuous so as to extend across the width of the pallet 20 , ie, between the corner support blocks 50 .

[0061] With respect to the corner support block 50, a centerline mark 186 is carried by the exposed corner surface 170 extending between the pair of exposed side surfaces 52, 54. As shown. The centerline mark 186 can be placed at the center of the exposed corner. Alternatively, the centerline mark 186 can be continuous along the length or height of the exposed corner surface 170. The continuous centerline mark can also include gaps or broken lines to indicate the center of the corner support block 50.

[0062] The centerline markings 184 on the intermediate support blocks 80 are similar to the centerline markings on the corner support blocks 50. Each centerline marking 184 on the intermediate support blocks 80 is carried by an exposed support block corner surface 86.

[0063] Another aspect is directed to a method for manufacturing a pallet 20 having centerline markings 180, 182, 184, 186 as described above. The method includes forming a top deck 30 having a rectangular shape, forming a bottom deck 40 having a rectangular shape, and coupling a plurality of spaced-apart corner support blocks 50 and a plurality of intermediate support blocks 80 between the top and bottom decks and forming gaps therebetween for receiving a lifting member. The centerline markings 180, 182, 184, 186 are attached to at least one of the top deck 30, the bottom deck 40, and the plurality of corner and intermediate support blocks 50, 80 to provide a visual aid for an operator of the lifting member.

[0064] Reference now Fig.10 and 11 , another aspect of the plastic pallet 20 is directed to the corner support blocks 50, each of which has an upper tower 210 that is received by a corresponding upper tower opening 220 in the top deck 30. The upper tower 210 advantageously provides shear load transfer when impacted with the teeth of a forklift or pallet jack. Similarly, the intermediate support blocks 80 also have upper towers. The discussion of the upper tower 210 for the corner support blocks 50 also applies to the intermediate support blocks 80.

[0065] The top deck 30 has a rectangular shape with spaced-apart upper and lower surfaces. The lower surface 31 of the top deck 30 has a plurality of upper tower openings 220 therein.

[0066] Each corner support block 50 includes an outer wall 51 surrounding a central area, and a core structure 200 having a rectangular shape in the central area. The upper surfaces of the core structure 200 and the outer wall 51 are coplanar.

[0067] For example, the upper tower 210 extends outwardly from the core structure 200 and into a corresponding upper tower opening 220 in the top deck 30 to provide shear load transfer during impact with the lifting member. The core structure 200 and the upper tower 210 have a rectangular shape of the same size. In addition, the side walls of the core structure 200 are aligned with the side walls of the upper tower 210. Each support block 50 is formed as a unitary form or an integrally formed support block.

[0068] The first set of ribs 202 are between the exterior wall 51 and the core structure 200. The second set of ribs 204 are within the interior region of the upper tower 210. The first and second sets of ribs 202, 204 provide reinforcement to the corner support block 50 to improve impact performance.

[0069] Now refer to Fig.12 and 13 The interface of the corner support block 50 to the bottom deck 40 is discussed. The bottom deck 40 has spaced apart upper and lower surfaces, and the upper surface 41 has a plurality of pairs of raised openings 230 therein. The pairs of raised openings 230 are separated by a portion of the upper surface area 232 of the bottom deck 40. Each pair of raised openings 230 is aligned with a corresponding upper tower opening 220 in the top deck 30.

[0070] Each corner support block 50 also includes a pair of protrusions 53 that extend from the lower surface of the core structure 200 and into corresponding pairs of protrusion openings 230 in the bottom deck 40. The pair of protrusions 53 are separated by a portion 57 of the area of ​​the bottom surface of the core structure 200. The pair of protrusions 53 also advantageously provide shear load transfer during impact with the teeth of a forklift or pallet jack.

[0071] Portions 234 of the paired protrusion openings 230 in the bottom deck 40 are tapered. Similarly, portions 55 of the paired protrusions 53 on the support block 50 are also tapered. The tapered portions 234 of the paired protrusion openings 230 are angled toward the core structure 200, and the tapered portions 55 of the paired protrusions 53 are also angled toward the core structure. The tapered portions 55, 234 allow the paired protrusions 53 to be more easily inserted into the paired protrusion openings 230.

[0072] Once the top and bottom decks 30, 40 are joined to the corner and intermediate support blocks 50, 80, snap pins 250 may be used to hold the pallet 20 together, such as Figure 14-15 As shown. A snap pin 250 is inserted through each corner and intermediate support block 50, 80. An advantage of the snap pins 250 is that they act as a fusible link in the event that excessive separation forces are applied between the top and bottom decks 30, 40. This separation force can be generated when the wheels of the pallet jack rest on the bottom deck 40 and the teeth extending from the pallet jack are lifted upward. This causes the top deck 30 to become separated from the lower deck 40. When the separation forces become excessive, the snap pins 250 will snap or break. As a result, rather than replacing the entire top deck 30, the broken snap pins 250 are replaced.

[0073] The top deck 30 has an upper snap-in pin opening 260 extending therethrough, such as Fig.11 The bottom deck 40 has a lower snap-in pin opening 262 extending therethrough and aligned with the upper snap-in pin opening 260, as shown. Fig.13 More specifically, each upper snap-in pin opening 260 extends through a corresponding upper tower opening 220 in the top deck 30 . Each lower snap-in pin opening 262 extends between a corresponding pair of protrusion openings 230 in the bottom deck 40 .

[0074] The upper tower 210 in each corner support block 50 includes a snap pin channel 264 extending therethrough and aligned with the respective upper and lower snap pin openings 260, 262 in the top and bottom decks 30, 40. The second set of ribs 204 contacts the snap pin channel 264. The discussion of the snap pins 250 for the corner support blocks 50 also applies to the intermediate support blocks 80.

[0075] Each snap pin 250 includes a head end 252 for engaging an upper snap pin opening 260 in the top deck 30, a body 254 coupled to the head end and extending within a snap pin channel 264, and a pair of spaced-apart tips 256 coupled to the body and extending through the lower snap pin opening 262 for resiliently engaging the lower surface of the bottom deck 40.

[0076] The body 254 includes a pair of notches 270 to intentionally weaken the snap pin 250 so that the body snaps or breaks when excessive separation forces are applied between the top and bottom decks 30, 40. As will be readily appreciated by one skilled in the art, the notches 270 are sized so that the body 254 will snap or break at a predetermined breaking load.

[0077] The head end 252 of each snap pin 250 may be rectangular in shape. Each snap pin opening 260 in the upper deck 30 is correspondingly identically shaped. This helps to hold the snap pins 250 in place. The snap pins 250 are typically inserted into the pallet 20 after the upper and lower decks 30, 40 have been joined with the corner and intermediate support blocks 50, 80.

[0078] The spaced apart tips 256 of each bayonet pin 250 may be beveled to facilitate insertion thereof through the bayonet pin receiving cavity 264. Each tip 256 has a respective lip 258 for engaging the rear side of the bottom deck 40.

[0079] On the rear side of the bottom deck 40, the lower snap pin opening 262 is recessed. This is to allow room for the lip 258 on the tip 256 to pass through and engage the rear side of the bottom deck 40 without extending through the lower surface of the bottom deck, as shown in FIG. Fig.15 Similarly, the upper snap pin opening 260 in the top deck 30 is recessed. This allows for the head 252 of each snap pin 250 to pass through to engage with the upper snap pin opening 260 in the top deck 30 without extending through the upper surface of the top deck, as shown. Figure 2 shown.

[0080] The pallet 20 also includes a plurality of tubular inserts 300 carried by the top deck 30, such as Fig.16The tubular inserts 300 are along the perimeter of the top deck 30 and are diagonally positioned within the area surrounded by the perimeter. The tubular inserts 300 are metal and add strength and durability to the top deck 30. Although not shown, the bottom deck 40 also includes tubular inserts.

[0081] Tubular inserts 300 along the perimeter of the top deck 30 abut against the upper towers 210 in the corner and intermediate support blocks 50, 80. The top deck 30 is formed in a two-piece thermoforming process and has a thermoplastic upper sheet 31 fused to a thermoplastic lower sheet 33, as shown. Fig.17 Thus, the upper sheet 31 and the lower sheet 33 have a fused seam 37 along the peripheral edge of the upper deck 30. The bottom deck 40 is also formed in a two-piece thermoforming process.

[0082] Another aspect is directed to a method for manufacturing a pallet 20 having support blocks 50, 80 with upper towers 210 as described above. The method includes forming a top deck 30 having a rectangular shape, which has spaced-apart upper and lower surfaces (the lower surface 31 has a plurality of upper tower openings 22031 therein), and forming a bottom deck 40 having a rectangular shape. The method also includes coupling a plurality of spaced-apart support blocks 50, 80 between the top and bottom decks 30, 40 and forming gaps therebetween for receiving a lifting member. Each support block 50, 80 includes an outer wall 51 surrounding a central region, and a core structure 200 having a rectangular shape within the central region, and the upper surface and outer wall of the core assembly are coplanar. The upper towers 210 extend outwardly from the core structure 200 and into corresponding upper tower openings 220 in the top deck 30 to provide shear load transfer during impact with the lifting member. The first rib 202 may be between the exterior wall 51 and the core structure 200 , and the second rib 204 may be located within an interior region of the upper tower 210 .

[0083] Reference now Figure 18-20 Another embodiment of the support blocks 50, 80 is based on each support block 350 comprising separable inner and outer blocks 360, 380. If a support block 350 is damaged by impact from the teeth of a forklift or pallet jack, the inner block 380 or the outer block 350 can be replaced without having to replace the entire corner support block.

[0084] The outer block 360 has an open top surface exposing an inner block receiving area 362 therein, and has a bottom surface 364, and a first and second pair of opposing outer block side surfaces 366, 368 carried by the bottom surface. Each opposing outer block side surface 366, 368 has a pocket opening 370 therein, also for exposing the inner block receiving area 362.

[0085] The inner block 380 is inserted into the inner block receiving area 362 of the outer block 360. The inner block 380 includes first and second pairs of opposing inner block side surfaces 382, ​​384, and each opposing inner block side surface is aligned with the pocket opening 370 in the corresponding outer block side surface 366, 368 so that the pocket 410 is formed by covering the pocket opening.

[0086] The outer and inner blocks 360, 380 may be molded from thermoplastics or other polymeric materials, including high density polyethylene (HDPE), polypropylene (PP), and other polymeric materials. As will be appreciated by those skilled in the art, the polymeric materials may be filled or unfilled and / or may include particulate or fibrous, natural or synthetic materials, among other features. For example, unfilled HDPE may provide improved impact strength, PP with a reinforcement (i.e., long glass fibers) may provide improved structural properties, and unfilled PP with a random copolymer may provide improved reinforcement qualities.

[0087] Each of the outer and inner blocks 360, 380 may be formed of the same thermoplastic or polymer material. Alternatively, the outer block 360 may be formed of a first type of thermoplastic or polymer material and the inner block 380 may be formed of a second type of thermoplastic or polymer material.

[0088] Other embodiment support blocks, such as the corner support blocks 50 and the intermediate support blocks 80 described above, and the snap pins 250 may also be formed using thermoplastics or other polymer materials.

[0089] The first and second pairs of opposing inner block side surfaces 382, ​​384 of each inner block 380 surround the central region. Each inner block 380 also includes a core structure 390 having a rectangular shape within the central region.

[0090] The first set of ribs 392 are between the first and second pairs of opposing interior block side surface exteriors 382, ​​384 and the core structure 390. The second set of ribs 394 are within the interior region of the core structure 390.

[0091] When the inner block 380 and the outer block 360 are joined together, the first set of ribs 392 extend across the first and second pairs of opposing inner block side surface exteriors 382, ​​384 to contact the outer block 360. More specifically, the first set of ribs 392 contact adjacent side surfaces 412 of the pocket 410.

[0092] The top deck 30 has spaced apart upper and lower surfaces, and the lower surface 31 has a plurality of upper tower openings 220 therein, such as Fig.11Each interior block 380 also includes an upper tower 400 extending outwardly from the core structure 390 and into a corresponding upper tower opening 220 in the top deck 30 to provide shear load transfer during impact with the lift member.

[0093] The core structure 390 and the upper tower 400 have a rectangular shape of the same size. The side walls of the core structure 390 and the side walls of the upper tower 400 are aligned.

[0094] Each pocket 410 is recessed from adjacent outer edges of the top and bottom decks. Each outer block side surface 366, 368 having a pocket opening 370 formed therein includes an outer exposed wall 414 surrounding the pocket opening, and an adjacent side surface 412 extending between the outer exposed wall and the pocket opening. The inner block side surfaces 382, ​​384 aligned with the pocket opening 370 form the bottom surface of the pocket 410, while the adjacent side surface 412 is non-orthogonal relative to the outer exposed wall 414 and the bottom surface.

[0095] Each outer block 360 includes a respective exposed support block corner surface 416 extending between an outer block side surface 366 of a first pair of opposing outer block side surfaces and an adjacent outer block side surface 368 of a second pair of outer block sides.

[0096] The bottom deck 40 has spaced apart upper and lower surfaces, and the upper surface 41 has a plurality of pairs of protrusion openings 230 recessed therein. Each pair of protrusion openings 230 is aligned with a corresponding upper tower opening 220 in the top deck 30. Each support block also includes a pair of protrusions 420 extending from the lower surface of the core structure 390 and entering the corresponding pair of protrusion openings 230 in the bottom deck 40, as shown in FIG. Fig.13 shown.

[0097] Portions 234 of the pair of protrusion openings 230 in the bottom deck 40 are tapered, and portions 422 of the pair of protrusions 420 are tapered. The tapered portions 234 of the pair of protrusion openings 230 are angled toward the core structure 390. Similarly, the tapered portions 422 of the pair of protrusions 420 are angled toward the core structure 390.

[0098] The top deck 30 has a plurality of upper snap-in pin openings 260 extending through the plurality of tower assembly openings 220, such as Fig.11 Similarly, the bottom deck 40 has a plurality of lower snap-in pin openings 262 extending therethrough and aligned with the plurality of upper snap-in pin openings 260, as shown in FIG. Fig.13 The upper tower 400 in each support block 350 includes a snap pin passage 430 extending therethrough and aligned with the upper and lower snap pin openings 260, 262 in the top and bottom decks 30, 40, respectively. The snap pin 250 is inserted into the snap pin passage 430 as discussed above.

[0099] Another aspect is directed to a method for manufacturing a pallet 20 having a support block 350 including inner and outer blocks 360, 380 as described above. The method includes forming a top deck 30, forming a bottom deck 40, and a plurality of spaced apart support blocks 350 coupled between the top and bottom decks and forming gaps therebetween to receive a lifting member. Each support block 350 includes an outer block 360 having an open top surface with an inner block receiving area 362 exposed therein, and includes a bottom surface 364 and first and second pairs of opposing outer block side surfaces 366, 368 carried by the bottom surface. Each opposing outer block side surface 366, 368 has a pocket opening 370 therein, also for exposing the inner block receiving area. The inner block 380 is inserted into the inner block receiving area 362 of the outer block 360 and includes first and second pairs of opposing inner block side surfaces 382, ​​384. Each opposing interior block side surface 382 , 384 is aligned 370 with a pocket opening in a corresponding exterior block side surface 366 , 368 such that a pocket 410 is formed by encompassing the pocket opening.

[0100] Another embodiment of the above-mentioned support plate 20 will now be referred to Figure 21-27 Discussion In this embodiment, the plastic pallet 500 includes a support block 530 having upper and lower towers 550, 570, and an interlocking tower assembly 590 extending through the support block 530 for coupling the top and bottom decks 510, 520 together.

[0101] Fig. 22 5. A cross-sectional view of the pallet 500 through the center of the support block 530 is provided in FIG. The top deck 510 has a rectangular shape having spaced-apart upper and lower surfaces, and the lower surface has a plurality of upper tower openings 512 recessed therein and a plurality of stepped upper protrusions 514 protruding therefrom. Each stepped upper protrusion 514 is adjacent to a respective upper tower opening 512 to form a stepped interface of the top deck upper portion.

[0102] Similarly, the bottom deck 520 has a rectangular shape with spaced-apart upper and lower surfaces, and the upper surface has a plurality of lower tower openings 522 recessed therein and a plurality of stepped lower protrusions 524 protruding therefrom. Each stepped lower protrusion 524 is adjacent to a respective lower tower opening 522 to form a stepped interface of the bottom deck lower portion.

[0103] Spaced apart support blocks 530 are coupled between the top and bottom decks 510, 520 and form a gap therebetween for receiving a lifting member. The support blocks 530 may be configured as corner support blocks or intermediate support blocks. Each support block 530 includes an intermediate region 532 having spaced apart upper and lower surfaces. An upper tower 550 extends from the upper surface of the intermediate region 532. The upper surface has a stepped upper protrusion groove 534 adjacent to the upper tower 550 to form a stepped interface of the support block upper portion. The upper tower 550 is inserted into a corresponding upper tower groove 512 in the top deck 510, and the stepped upper tower protrusion groove 534 receives a corresponding stepped upper tower protrusion 514 from the top deck 510, so that the stepped interface of the top deck upper portion contacts the stepped interface of the support block upper portion to provide shear load transfer during impact with the lifting member.

[0104] The lower tower 570 extends from the lower surface of the intermediate zone 532. The lower surface has a stepped lower protrusion groove 536 adjacent to the lower tower 570 to form a support block lower stepped interface. The lower tower 570 is inserted into a corresponding lower tower groove 522 in the bottom deck 520, and the stepped lower tower protrusion groove 536 receives a corresponding stepped lower tower protrusion 524 from the bottom deck 520, so that the bottom deck lower stepped interface contacts the support block lower stepped interface to provide shear load transfer during impact with the lifting member.

[0105] The pallet 500 also includes interlocking tower assemblies 590 extending between the top and bottom decks 510, 520 and through the support blocks 530. Each interlocking tower assembly 590 includes a tubular section 592 carried by the bottom deck 520 and having an end 594 that contacts the lower surface of the top deck 520. The end 594 can be straight or flared as shown. An insert 602 is carried by the top deck 510 and has a tapered end 604 that is inserted into the end 594 of the tubular section 592.

[0106] The tubular region 592 includes a biasing member 596, and the insert 602 includes a catch 606 that engages the biasing member. The biasing member 596 is shown as a spring, and the catch 606 is a groove along the side wall of the insert 602. The spring 596 releases the groove 606 at a predetermined load.

[0107] The interlocking tower assembly 590 that couples the top and bottom decks 510, 520 together is Fig.23 530 is shown without the support block 530 in place. The sheet metal 511 carried by the top deck 510 is used to secure the insert 602 to the top deck 510, and the sheet metal 511 carried by the bottom deck 520 is used to secure the tubular section 592 to the bottom deck 520, as shown in FIG. Fig.23 and 24 shown.

[0108] like Fig.24 As shown, the insert 602 is fully seated in the tubular region 592. When the teeth of the pallet jack are inserted too far between the top and bottom decks 510, 520, causing the wheels of the pallet jack to rest on the bottom deck, the biasing members 596 in the tubular region begin to separate from the detents 606 in the insert 602 when force is applied, as shown in FIG. Fig.25 shown.

[0109] Once the biasing member 596 allows the detent 606 to pass, the top deck 510 is separated from the bottom deck 520, as shown in FIG. Fig.26 To reset the connection, the tapered end 604 of the insert 602 is inserted into the flared end 594 of the tubular section 592, as shown. Fig. 27 This configuration advantageously provides a consistent reset.

[0110] The middle region of each support block 532 includes first and second pairs of opposing exposed support block side surfaces 610, 620. Each exposed support block side surface 610, 620 has a pocket 630 formed therein for receiving the end of a lifting member to allow the pallet to be turned. Each pocket 630 is recessed from adjacent outer edges of the top and bottom decks 510, 520.

[0111] Each exposed support block side surface 610, 620 having a pocket 630 formed therein includes an outer exposed wall 640 surrounding the pocket. The pocket 630 includes a bottom surface 642 and adjacent side surfaces 644 that are non-non-orthogonal relative to the outer exposed wall and bottom surface.

[0112] The intermediate region 532 of each support block includes a respective exposed support block corner surface 650 extending between an exposed support block side surface 610 in the first pair of exposed support block side surfaces and an adjacent exposed support block side surface 620 in the second pair of exposed support block side surfaces.

[0113] The pallet 500 also comprises tubular inserts 660 carried by the top deck 510 along its outer edge. Each tubular insert 660 abuts against at least one upper tower 550.

[0114] Another aspect is directed to a method for manufacturing a pallet 20 having a support block 530 with upper and lower towers 550, 570 as described above. The method includes forming a top deck 510 having a rectangular shape and forming a bottom deck 520 having a rectangular shape. The top deck 510 includes spaced-apart upper and lower surfaces, and the lower surface has a plurality of upper tower openings 512 recessed therein and a plurality of stepped upper protrusions 514 protruding therefrom. Each stepped upper protrusion 514 includes an adjacent respective upper tower opening 512 to form a stepped interface on the top deck.

[0115] The bottom deck 520 includes spaced apart upper and lower surfaces, and the upper surface has a plurality of lower tower openings 522 recessed therein and a plurality of stepped lower protrusions 524 protruding therefrom. Each stepped lower protrusion 524 is adjacent to a respective lower tower opening 522 to form a stepped interface of the bottom deck lower portion.

[0116] The method further includes forming a plurality of spaced apart support blocks 530 between the top and bottom decks 510, 520 and forming gaps therebetween to receive the lifting member. Each support block 530 includes a middle section 532 having spaced apart upper and lower surfaces, and an upper tower 550 extending from the upper surface of the middle section 532. The upper surface may have a stepped upper protrusion opening 534 adjacent to the upper tower 550 to form a support block upper stepped interface. The upper tower 550 may be inserted into a corresponding upper tower opening 512 in the top deck 510, and the stepped upper tower protrusion opening 534 receives a corresponding stepped upper tower protrusion 514 from the top deck 510, so that the top deck upper stepped interface contacts the support block upper stepped interface to provide shear load transfer during impact with the lifting member.

[0117] The lower tower 570 extends from the lower surface of the middle section 532, and the lower surface has a stepped lower protrusion opening 536 adjacent to the lower tower 570 to form a support block lower stepped interface. The lower tower 570 is inserted into a corresponding lower tower opening 522 in the bottom deck 520, and the stepped lower tower protrusion opening 536 receives a corresponding stepped lower tower protrusion 524 from the bottom deck 520, so that the bottom deck lower stepped interface contacts the support block lower stepped interface to provide shear load transfer during impact with the lifting member.

[0118] Many modifications and other embodiments of the present invention will be apparent to those skilled in the art who have benefited from the teachings presented in the foregoing description and the associated drawings. Therefore, it should be understood that the present invention is not limited to the particular embodiments disclosed, and modifications and embodiments are intended to be included that are readily understood by those skilled in the art.

Claims

1. A pallet, comprising: a top deck having a rectangular shape and four external exposed edges; a bottom deck having a rectangular shape and four external exposed edges; a plurality of spaced-apart corner support blocks and a plurality of intermediate support blocks coupled between the top deck and the bottom deck and forming a plurality of corresponding gaps therebetween and along the four outer exposed edges of the top deck and the bottom deck for receiving a lifting member through any of the four outer exposed edges; as well as a plurality of centerline markings on at least two of the four outer exposed edges on each side of the top deck and the bottom deck between the plurality of corner support blocks and the plurality of intermediate support blocks to provide a forward-facing visual aid to an operator of the lifting member to position the lifting member in two of the plurality of gaps, each centerline marking on the outer exposed edges of the top deck and the bottom deck having a broken line in the centerline marking to indicate the center of the corresponding gap between the corner support block and the intermediate support block, and each centerline marking comprises pre-molded plastic having a first color surrounded by molded plastic having a second color, the first color being lighter than the second color.

2. The pallet of claim 1, wherein each centerline marking comprises a reflective material.

3. The pallet of claim 1, wherein each centerline marking is recessed relative to a mounting surface on at least one of the top deck and the bottom deck.

4. The pallet of claim 1, wherein each corner and intermediate support block comprises: first and second pairs of opposing exposed support block side surfaces; a corresponding exposed support block corner surface extending between an exposed support block side surface in the first pair of exposed support block side surfaces and an adjacent exposed support block side surface in the second pair of exposed support block side surfaces; as well as The plurality of centerline markings include a centerline marking carried by each exposed support block corner surface.

5. A pallet according to claim 1, wherein each corner and intermediate support block includes a first and second pair of relatively exposed support block side surfaces, each exposed support block side surface having a pocket formed therein for receiving an end of the lifting member to allow the pallet to be turned.

6. The pallet of claim 5, wherein for each exposed support block side surface aligned with adjacent outer edges of the top deck and the bottom deck, a corresponding pocket in the exposed support block side surface is recessed from the adjacent outer edges.

7. A pallet according to claim 5, wherein each exposed support block side surface block having the pocket portion formed therein includes an external exposed wall surrounding the pocket portion, and wherein the pocket portion includes a bottom surface and an adjacent side surface, and the adjacent side surface is non-orthogonal relative to the external exposed wall and the bottom surface.

8. A method for manufacturing a pallet, the method comprising: forming a top deck having a rectangular shape and an externally exposed edge; forming a bottom deck having a rectangular shape and an outer exposed edge; coupling a plurality of spaced-apart corner support blocks and a plurality of intermediate support blocks, the plurality of spaced-apart corner support blocks and the plurality of intermediate support blocks being coupled between the top deck and the bottom deck and forming a gap therebetween for receiving a lifting member; as well as A plurality of centerline markings are provided on the outer exposed edges of each side of the top deck and the bottom deck between the plurality of corner support blocks and the plurality of intermediate support blocks to provide a visual aid to an operator of the lifting structure, each centerline marking on the outer exposed edges of the top deck and the bottom deck having a broken line in the centerline marking to indicate the center of the gap between the corner support block and the intermediate support block, and each centerline marking comprises pre-molded plastic having a first color surrounded by molded plastic having a second color, the first color being lighter than the second color.

9. The method of claim 8, wherein each exposed support block side surface has a pocket formed therein for receiving an end of a lifting member to allow the pallet to be turned.

10. The method of claim 8, wherein for each exposed support block side surface aligned with adjacent outer edges of the top deck and the bottom deck, the corresponding pocket in the exposed support block side surface is recessed from the adjacent outer edges.

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