Half size plastic pallet with grommets on top deck

Abstract

To provide a reconfigurable pallet.SOLUTION: The pallet includes: an upper deck having a plurality of grommet openings extending through the upper deck, each grommet opening including a recessed shelf and a divider below the recessed shelf; a plurality of grommets that are inserted into the plurality of grommet openings and are upper sections with upper lips resting on the recessed shelf, the outer exposed surface of the upper section extending above the upper deck; a pair of central sections extending from the upper deck to a lower side of the upper deck, each central section separated by a divider; and a pair of lower sections extending from the pair of central sections, the outer exposed surface of each lower section extending at a height below the lower side of the upper deck.SELECTED DRAWING: Figure 16

Description

[Technical field]

[0001] The present disclosure relates to the field of pallets, and more specifically to half size plastic pallets. [Background technology]

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 760,218, filed November 13, 2018, which is incorporated by reference in its entirety.

[0003] Retailers often prefer to use split pallets to display products for customers to purchase. Split pallets are usually one-quarter to one-half the size of a full-size pallet. Split pallets have a much smaller footprint, allowing retailers to display a variety of products in an area the same size as a full-size pallet.

[0004] Additionally, retailers often prefer to use plastic split pallets rather than wooden split pallets, which are more aesthetically pleasing and hygienic than wooden split pallets.

[0005] In view of current split plastic pallets, there remains a need for a split plastic pallet that is easily moved by pallet handling equipment and that also allows for aesthetically acceptable product display. Because the products carried on split plastic pallets can be relatively heavy, the load-bearing capacity of the pallet should not be sacrificed while providing accessibility. Summary of the Invention [Means for solving the problem]

[0006] The pallet includes an upper deck having grommet openings extending therethrough, each grommet opening including a recessed shelf. The pallet support legs are coupled to an underside of the upper deck. The grommets are inserted into the grommet openings. Each grommet includes an upper section including an upper lip that rests on the recessed shelf, an outer exposed surface of the upper section extending to an elevation above the upper deck. At least one central section is adjacent to the upper lip and extends from the upper section to the underside of the upper deck. The at least one lower section includes a pair of spaced apart lower lips extending from the at least one central section and resting on the underside of the upper deck. An outer exposed surface of the at least one lower section extends at an elevation less than the underside of the upper deck.

[0007] Each grommet opening may further include a divider, and the at least one central section may include a pair of spaced apart central sections, each central section separated by a divider, and the at least one lower section includes a pair of lower sections, each lower section extending from a respective central section.

[0008] The divider may include the underside or underside of the upper deck. The divider may include the upper surface underlying the recessed shelf.

[0009] The grommet openings are disposed adjacent a periphery of the upper deck, and each grommet opening and each grommet is rectangular.

[0010] Each grommet may comprise at least one of natural rubber and synthetic rubber.The top deck and the pallet support legs may be constructed of plastic.

[0011] Another aspect is directed to a method for manufacturing a pallet as described above with grommets in the top deck. The pallet includes a top deck having grommet openings extending therethrough, each grommet opening including a recessed shelf. A grommet is inserted into the grommet opening. Each grommet includes an upper section with an upper lip resting on the recessed shelf, an outer exposed surface of the upper section extending at an elevation above the top deck. At least one central section is adjacent to the upper lip and extends from the upper section to a lower surface of the top deck. At least one lower section includes a pair of spaced apart lower lips extending from the at least one central section and resting on the lower surface of the top deck. An outer exposed surface of the at least one lower section extends at an elevation below the lower surface of the top deck. The method further includes forming a pallet support leg, coupling the pallet support leg to the lower surface of the top deck, and forming an opening below the top deck for receiving a lift member. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a top perspective view of a half-size plastic pallet according to the present disclosure. [Diagram 2] FIG. 2 is a perspective view of the half-size plastic pallet shown in FIG. 1 as seen from below. [Diagram 3] FIG. 3 is a top perspective view of a pallet support leg for the half size plastic pallet shown in FIGS. 1 and 2. FIG. [Figure 4] FIG. 4 is a top view of the pallet support leg shown in FIGS. 1 and 2. [Diagram 5] FIG. 5 is a bottom view of the pallet support leg shown in FIGS. 1 and 2. [Figure 6] 6 is a perspective view of a plug to be inserted into the reinforcing bar opening of the pallet support leg shown in FIG. 3; FIG. [Figure 7] FIG. 7 is a perspective view of the upper deck shown in FIG. 1 as viewed from above. [Figure 8]FIG. 8 is a top view of the upper deck shown in FIG. [Figure 9] FIG. 9 is a top perspective view of one of the product display attachment points shown in FIG. [Figure 10] FIG. 10 is a perspective view of the upper deck shown in FIG. 7 as seen from the bottom side. [Figure 11] FIG. 11 is a bottom view of the upper deck shown in FIG. [Figure 12] FIG. 12 is a cross-sectional side view of the upper deck shown in FIG. [Figure 13] FIG. 13 is a side view of the half-size plastic pallet shown in FIG. [Figure 14] FIG. 14 is an end view of the half size plastic pallet shown in FIG. [Figure 15] FIG. 15 is an isolated view of the grommet opening in the top deck shown in FIG. [Figure 16] FIG. 16 shows various views of the grommet shown in FIGS. [Figure 17] FIG. 17 shows various views of the grommet shown in FIGS. [Figure 18] FIG. 18 shows various views of the grommet shown in FIGS. [Figure 19] FIG. 19 shows various views of the grommet shown in FIGS. [Figure 20] FIG. 20 shows various views of the grommet shown in FIGS. [Figure 21] FIG. 21 shows various views of the grommet shown in FIGS. [Figure 22] FIG. 22 is a side view of the half-size plastic pallet shown in FIG. 1 stacked on another half-size plastic pallet. [Diagram 23] FIG. 23 is a cross-sectional side view of the stacked half size plastic pallets shown in FIG. [Figure 24]FIG. 24 is a top perspective view of the upper deck shown in FIG. 7 configured as a dolly. [Diagram 25] FIG. 25 is a perspective view of the dolly shown in FIG. 24 as seen from the bottom side. [Figure 26] FIG. 26 is a side view of the dolly shown in FIG. [Figure 27] FIG. 27 is an end view of the truck shown in FIG. [Figure 28] FIG. 28 is a top perspective view of the dolly shown in FIG. 24 stacked on another dolly. [Figure 29] FIG. 29 is a side view of the stacked dollies shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The description will now be made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the specific embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0014] 1 and 2, the illustrated half size plastic pallet 20 includes a top deck 30 and three removable pallet support legs 40 coupled to the top deck. The pallet support legs 40 are removable from the top deck 30, which allows the half size plastic pallet to be easily repaired in the event that the pallet support legs 40 or the top deck 30 are damaged.

[0015] The three pallet support legs 40 include a pair of outer pallet support legs and a center pallet support leg. The pallet support legs 40 are configured to allow four-way access by pallet handling equipment, such as a forklift or pallet jack. As described in more detail below, the plastic pallet 20 is serviceable, stackable, and includes mounting locations for product displays.

[0016] The half size plastic pallet 20 is 24 inches by 40 inches in size. Even though the disclosed features of the plastic pallet 20 relate to a half size pallet, these features may be used with other size plastic pallets. The plastic pallet 20 may be sized, for example, 24 inches by 20 inches, and may be reduced to a quarter size. The plastic pallet 20 may be sized, for example, 48 inches by 40 inches, and may be expanded to full size. These dimensions may be adjusted to accommodate countries that use the metric system.

[0017] The top deck 30 includes an upper surface referred to as the product support surface 32 and an opposite lower surface referred to as the lower surface 34. The top deck 30 has an outer exposed surface extending between the product support surface 32 and the opposite lower surface 34. The outer exposed sides include spaced apart outer side surfaces 36 and spaced apart outer side surfaces 38. The outer side surfaces 36 correspond to the length of the half size plastic pallet 20 and the outer side surfaces 38 correspond to the width or ends of the half size plastic pallet 20. The length is the longer dimension than the dimension of the half size plastic pallet 20 (i.e., 40 inches) while the width is the shorter dimension than the dimension of the half size plastic pallet 20 (i.e., 24 inches).

[0018] The outer pallet support legs 40 are aligned with the outer sides 38, i.e., the outer sides 38 are parallel to the pallet support legs 40. Each pallet support leg 40 has a length that is the same as the dimension of the outer sides 38, i.e., each pallet support leg 40 extends across the width of a half size plastic pallet 20.

[0019] 3-6, each pallet support leg 40 includes a base 42 and a base support element 52, 72 extending from the base 42. The base support elements 52, 72 are coupled to the underside 34 of the top deck 30. The base support element 52 may be referred to as an outer base support element, while the base support element 72 may be referred to as a central base support element. The outer and central base support elements 52, 72 are integrally formed with the base 42.

[0020] Each outer base support element 52 has a lower end formed integrally with the base 42 and an exposed upper end. A pair of outwardly facing snaps 54 extend from the exposed upper ends to contact the underside 34 of the top deck 20. Similarly, a pair of inwardly facing snaps 56 extend from the exposed upper ends 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, thereby coupling the outer base support elements 52 to the top deck 30.

[0021] The underside 34 of the top deck 30 further has a plurality of guide openings 172 adjacent the plurality of snap openings 170. Also extending from the exposed upper end of the outer base support element 52 are a pair of spaced apart guides 58. The guides 58 are configured to align the snaps 54, 56 with the snap openings 170. The guide openings 172 correspond to the profile of the outer base support element 52, as defined by the outwardly facing sidewall 51, the inwardly facing sidewall 53, and the pair of curved end walls 55. The dimensions of the guide openings 172 in the underside 34 of the top deck 30 are smaller than the dimensions of the profile of the outer base support element 52 in order to receive the guides 58.

[0022] 10, the snap openings 170 for the outwardly facing snaps 54 are oriented outwardly to be exposed through the outer side 36 of the top deck 30, while the snap openings 170 for the inwardly facing snaps 56 are oriented inwardly and are not exposed. The height of the guide 58 may be the same as the height of the snaps 54, 56. In other embodiments, the height of the guide 58 may be different than the height of the snaps 54, 56.

[0023] Outer base support element 52 has an outwardly facing sidewall 51 with a pair of outwardly facing snaps 54 extending therefrom and a spaced apart inwardly facing sidewall 53 with a pair of inwardly facing snaps 56 extending therefrom. The pair of outwardly facing snaps 54 are recessed from outwardly facing sidewall 51. The pair of inwardly facing snaps 56 are recessed from inwardly facing sidewall 53.

[0024] A pair of curved end walls 55 are at the ends of the outwardly and inwardly facing side walls 51 and 53, and a 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 are recessed from the pair of curved end walls 55.

[0025] Each snap 54, 56 includes a flexible snap element 60, a lip 62 extending outwardly from the snap element 60, and a sloped surface or edge 64 between the lip 62 and the snap element 60. The sloped surface 64 and lip 62 bendably engage with a corresponding snap opening 170 in the underside 34 of the top deck 30.

[0026] The central base support element 72 has a lower end formed integrally with the base 42 and an exposed upper end. Two pairs of outwardly facing snaps 74 extend from the exposed upper end to contact the underside 34 of the top deck 20. The snaps 74 are configured to engage snap openings 180 in the underside 34 of the top deck 30. As shown in FIG. 10 , the snap openings 180 for the outwardly facing snaps 74 are in the underside 34 of the top deck 30 and are not exposed through either of the outer sides 36, 38.

[0027] The underside 34 of the top deck 30 further has a plurality of guide openings 182 adjacent to a plurality of snap openings 180. Also extending from the exposed upper end of the central base support element 72 are two pairs of spaced apart guides 78. 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 of the central base support element 72 defined by the walls 73. The dimensions of the guide openings 182 in the underside 34 of the top deck 30 are smaller than the dimensions of the profile of the central base support element 72 to receive the guides 78.

[0028] The central base support element 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 may be the same as the height of the snaps 74. In other embodiments, the height of the guides 78 may be different from the height of the snaps 74.

[0029] Each snap 74 includes a flexible snap element 80, a lip 82 extending outwardly from the snap element 80, and a sloped surface or edge 84 between the lip 82 and the snap element 80. The sloped surface 84 and lip 82 flexibly engage with a corresponding snap opening 180 in the underside 34 of the top deck 30.

[0030] The central base support element 72 further includes a ribbed core portion 90. Additionally, the core portion 90 also extends from the exposed upper end. The height of the core portion 90 is less than the height of the snaps 74.

[0031] Each pallet support leg 40 is identical to the others. The base 42 of each pallet support leg 40 includes an opening 44 for receiving a reinforcing bar. The reinforcing bar adds strength and durability to the pallet support leg 40. The reinforcing bar may be, for example, but not limited to, steel or metal. The base 42 includes spaced apart openings 46 through which the reinforcing bar is exposed. After the reinforcing bar is inserted into the opening 44, a plug 45, as shown in FIG. 6, is inserted into the opening 44 to retain the reinforcing bar therein. The opening 44 may be sized to receive, for example, a half ½ inch or ⅝ inch plug 45.

[0032] Each pallet support leg 40 may be formed from a thermoplastic or polymeric material. Similarly, the top deck 30 may also be formed from a thermoplastic or polymeric material. The plastics used in the half size plastic pallet 20 may be recyclable.

[0033] Another aspect relates to a method for manufacturing a pallet 20 with removable pallet support legs 40 as described above. The method includes forming a top deck 30 with a product support surface 32 and an opposing underside surface 34 having a plurality of snap openings 170 therein. The method further includes forming a plurality of pallet support legs 40. Each pallet support leg 40 includes a base 42 that extends across the width of the top deck 30 and a pair of outer base support elements 52. Each outer base support element 52 has a lower end integrally formed with the base 42 and an exposed upper end. A pair of outwardly facing snaps 54 extend from the exposed upper end of each outer base support element 52 to contact the underside surface 34 of the top deck 30. A pair of inwardly facing snaps 56 extend from the exposed upper end of each outer base support element 52 to contact the underside surface 34 of the top deck 30. The method further includes engaging the pair of outward and inward snaps 54 , 56 with respective snap openings 170 in the underside 34 of the top deck 30 to couple the pallet support leg 40 to the top deck 30 .

[0034] The top deck 30 will now be described in more detail with reference to Figures 7-9. The top deck 30 is integrally formed and includes four quadrants 100(1)-100(4). Each quadrant may be generally referred to as a quadrant 100. The quadrants 100 are of symmetrical design, with the exception of the shrink-wrap gripping members 110 in only quadrants 100(1) and 100(3).

[0035] The shrink wrap gripping members 110 are used to apply and hold shrink wrap to products carried by the top deck 30. Shrink wrap is typically used to secure products to a pallet, which is often an alternative to strapping, although both can be applied if desired.

[0036] A problem that arises when applying shrink wrap to a pallet is securing the edges of the shrink wrap, a problem that is faced both at the beginning and end of shrink wrapping because the wrap may not want to adhere to the product or the pallet, or may ultimately fail to stay on the product on the pallet.

[0037] The shrink-wrap gripping members 110 are disposed along the sides 36 of the top deck 30. There is one shrink-wrap gripping member 110 on each side 36, i.e., quadrants 100(1) and 100(3). In other embodiments, quadrants 100(2) and 100(4) may also include shrink-wrap gripping members 110 such that all of the quadrants 100 are symmetrical in design.

[0038] Each shrink wrap gripping member 110 is in the shape of a double-sided groove, similar to the shape of an anvil. The double-sided groove has a front recess and a rear recess with a narrow opening between them. The narrow opening allows the shrink wrap to be placed into the groove and makes it difficult for the wrap to re-exit the groove. The wrap can be pulled into the front or rear recess, which can secure the end of the wrap at the beginning or end of the wrapping process.

[0039] Another feature of the top deck 30 is that it includes grooves 150 for use as tie-down strap locations. A pair of grooves 150 are located on each of the longer sides 36 of the top deck 30.

[0040] Each quadrant 100 includes a hand access hole 102. The hand access holes 102 provide an easy means for an operator to handle the half size plastic pallet 20. The hand access holes 102 are large enough for a user to insert all four fingers therein. By providing hand access holes 102 in each quadrant 100, the half size plastic pallet 20 can be very easily grasped by a user for transporting it or removing it from a stack of pallets.

[0041] The top deck 30 includes several different merchandise display mounting locations for securing merchandise displays or boxes to the half size plastic pallet 20. When the half size plastic pallet 20 is, for example, loaded with merchandise and resting on the floor in a store, the merchandise displays serve to promote the merchandise. U.S. Patent No. 9,387,953 discloses a partial plastic pallet with merchandise display mounting locations and is incorporated herein by reference in its entirety. U.S. Patent No. 9,387,953 is assigned to the present assignee of the present invention.

[0042] The product display attachment points include display mounting slots 120, 130, and 150 in the product support surface 32, as shown in Figure 9. Each display mounting slot 120, 130, and 150 is rectangular in shape and sized to receive a tab that depends from the base of the product display so that the product display is held in place on the half size plastic pallet 20.

[0043] A pair of display mounting slots 120 are positioned adjacent each side 36, 38 of the top deck 30 for a total of eight display mounting slots 120. The product support surface 32 also has eight display mounting slots 130 and eight display mounting slots 150. Each display mounting slot 130 is aligned with a respective display mounting slot 120, and each display mounting slot 150 is recessed from the sides 36, 38 of the top deck 30 and is also aligned with a respective display mounting slot 130.

[0044] 9, each display mounting 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 closed bottom 136 that forms a curved shelf. The inner slot 138 is adjacent the curved shelf 136 and is recessed below the outer slot 132. The inner slot 138 has a pair of spaced apart side walls 140 and 142 and a closed bottom 144.

[0045] Within the inner slot 132, the sidewall 140 includes a protrusion 145 extending therefrom and the opposing sidewall 142 includes a tapered member 146 extending therefrom. The tapered member 146 has a downward taper towards the protrusion 145. When the product display tab has a properly positioned hole, the hole can engage and secure with the protrusion 145 or the tapered member 146.

[0046] Sidewall 142 with tapered member 146 is curved to correspond to curved shelf 136, while sidewall 140 with protrusion 145 is not curved. Tapered member 146 includes a bottom surface 148 that is perpendicular to closed bottom 144 of inner slot 138. There is a gap between flat underside 148 and closed bottom 144. Protrusion 145 has, for example, a quarter sphere shape. Tapered member 146 is aligned with the center of protrusion 145.

[0047] Each display mounting slot 150 is recessed from a side 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 mounting slot 150. The removal of the corresponding side 36, 38 of the display mounting slot 150 is uniform to form a pair of spaced apart retention tabs 151 for securing the product display tabs. The retention tabs 151 are at the top of the display mounting slot 150, while the bottom of the display mounting slot 150 is completely exposed.

[0048] The top deck 30 also includes openings 160, 162 for receiving reinforcing bars, as shown in FIG. 7. The reinforcing bars add strength and durability to the top deck 30. The reinforcing bars may be, for example, but not limited to, steel or metal. Side 38 has three openings 160 and side 36 has two openings 162 for receiving the reinforcing bars. After the reinforcing bars are inserted into the openings 160, 162, plugs 45, as shown in FIG. 6, are inserted into the openings 160, 162 to hold the reinforcing bars. The openings 160, 162 may be sized to receive, for example, 1 / 2 inch or 5 / 8 inch plugs 45.

[0049] As discussed above, the half size plastic pallet 20 is repairable. The pallet support legs 40 are formed separately from the top deck 30, and the top deck 30 is removable from the pallet support legs 40 for pallet repair. Each support leg 40 includes snaps 54, 56 associated with the outer base support elements 52 and a snap 74 associated with the central base support element 72. Each snap 54, 56 and 74 secures each pallet support leg 40 to the bottom surface 34 of the top deck 30.

[0050] The snaps 74 associated with the central base support element 72 secure to corresponding snap openings 180 exposed in the underside 34 of the top deck 30. Similarly, the snaps 54, 56 associated with the outer base support elements 50 secure to corresponding snap openings 170 exposed in the underside 34 of the top deck 30. The outer snap pins 52 are visible from the side 36 of the top deck 30.

[0051] The product support surface 32 of the top deck 30 includes an opening to receive a jig that is used to remove the pallet support legs 40. The jig contacts all of the snaps 54, 56, 74 on the pallet support legs 40, allowing them to unsnap from the underside 34 of the top deck 30.

[0052] The four substantially symmetrical quadrants 100 will now be described in more detail with reference to Figures 10-12. Each quadrant 100 includes a pair of spherical carvings 200, 210. The spherical carvings 200, 210 may also be referred to as deck scoop regions. The spherical carvings 200, 210 each reduce the thickness of the upper deck 30 in each quadrant 100. The spherical carvings 200, 210 advantageously reduce the effect of deflection in the center quadrant on the ability of the fork tines to pass through openings under the upper deck 30. Deflection may occur in the center quadrant when the half size pallet 20 is under heavy load.

[0053] In other embodiments, each quadrant 100 may include a single spherical carving, such as spherical carving 200 or 210. In yet other embodiments, the single spherical carving may overlap between spherical carvings 200 or 210.

[0054] The spherical carving 200 may be referred to as a first deck scoop area, and the spherical carving 210 may be referred to as a second deck scoop area. The second deck scoop area 210 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.

[0055] The underside 34 of the top deck 30 is constructed with exposed ribs. The first deck scoop area 200 includes a respective hand access hole 102. The hand access hole 102 is centered within the first deck scoop area 200. The hand access hole 102 is at the apex of the curvature of the first deck scoop area 200. This apex corresponds to the point of minimum thickness of the top deck 30 within the first deck scoop area 200.

[0056] Hand access hole 102 includes walls 103 that extend from product support surface 32 to the opposing underside 34 of top deck 30. Exposure rib 202 extends in a first direction and exposure rib 204 extends in a second direction orthogonal to the first direction within first deck scoop area 200.

[0057] The first deck scoop area 200 of each quadrant 100 is adjacent to the outer side 38 of the upper deck 30. A perimeter area 215 of the quadrant 100 between the outer side 38 and the first deck scoop area 200 has a uniform thickness and is not part of the first deck scoop area 200. The perimeter area 215 of the quadrant 100 extends around the perimeter of the upper deck 30 for all four quadrants. The perimeter area is adjacent to the outer sides 36 and 38.

[0058] The second deck scoop region 210 is separated from the first spherical carving 200 by a transition wall 220. The thickness of the upper deck 30 does not decrease at the transition wall 220. The ribs in the second deck scoop region 210 include ribs 212 extending in a first direction and ribs 214 extending in a second direction perpendicular to the first direction.

[0059] The second deck scoop area 210 includes a plurality of spaced apart openings 230 in each quadrant 100, as shown in FIG. 8. The openings 230 extend to the underside 34 of the upper deck 30. The openings 230 may be divided into spaced apart opening sections arranged in a grid. Each opening section has a pattern of openings 230 that is symmetrical with each of the other opening sections in each second deck scoop area 210.

[0060] Another aspect relates to a method for manufacturing a pallet 20 with deck scoop areas 200, 210 as described above. The method includes forming a top deck 30 divided into quadrants 100 and forming a plurality of pallet support legs 40. The pallet support legs 40 are coupled to an underside 34 of the top deck 30 and form openings below the top deck 30 for receiving lift members. The top deck 30 is formed to include at least one deck scoop area 200, 210 on the underside 34 in each quadrant 100. The thickness of the top deck 30 is reduced at each deck scoop area 200, 210 to reduce the effect of deflection of the top deck on the passage of lift members through the openings while below the top deck 30.

[0061] The top deck 30 may further be configured with provisions to allow for the attachment of an electronic tracking device. A compartment may be formed or attached to the underside 34 of the top deck 30, for example, to carry the electronic tracking device. Fasteners may be used attachments including screws or other hardware, plastic clips, or combinations thereof. The electronic tracking device may be configured to store data during use of the pallet. The electronic tracking device may include communication protocols such as, but not limited to, Bluetooth, Bluetooth Low Energy (BLE), RFID, cellular, GPS, etc.

[0062] 13-21, the use of grommets 250 in the top deck 30 will now be described. The grommets 250 advantageously provide a favorable grip when placed on the product support surface 32 of the top deck 30, and provide a favorable grip for forklift claws on the underside 34 of the top deck 30. The grommets 250 also advantageously help hold identical half size plastic pallets 20 in place when stacked on top of another half size plastic pallet 20. Suitable materials for the grommets 250 include, for example, natural and synthetic rubber.

[0063] Each quadrant 100 has a pair of grommets 250. One of the grommets 250 is in the perimeter region 215 of the upper deck 30. The other grommet 250 is in the second deck scoop region 210 and is orthogonal to the grommet 250 in the perimeter region 215. In the illustrated embodiment, there are eight grommets 250. The number, location, and size of the grommets 250 may vary as would be readily understood by one of ordinary skill in the art.

[0064] Each grommet 250 is inserted into a rectangular grommet opening 270 that extends through the top deck 30, as shown in FIG. 15. The grommet opening 270 forms a recessed shelf 272 that is stepped down from the upper surface 32 of the top deck 30. The grommet opening 270 has a first perimeter size above the recessed shelf 272.

[0065] Beneath the recessed shelf, the opening 270 has a second perimeter size that is smaller than the first perimeter size. Contained within the second perimeter size is a divider 274. The top surface of the divider 274 is recessed from the recessed shelf 272 and the bottom surface of the divider 274 is continuous with the underside 34 of the upper deck 30. The divider 274 requires that the bottom of each grommet 250 have an opening or gap 259 to accommodate the divider 274.

[0066] Each grommet 250 includes an upper section 253 that includes an upper lip 252 for engaging or resting on the recessed shelf 272. An upper surface 254 of each grommet 250 is flat and is raised above the product support surface 32 of the top deck 30. A transition 256 between the upper surface 254 and the upper lip 252 of each corresponding grommet 250 is curved.

[0067] A pair of central sections 258 extend from the upper section 253 of each grommet 250. The central sections 258 are on adjacent sides of the divider 274. A respective lower section 260 extends from each central section 258. The lower sections 260 extend to and flare outwardly to engage the underside 34 of the upper deck 30, as shown in FIG. 19. Each lower section 260 includes a lower lip 263 for engaging or resting on the underside 34 of the upper deck 30.

[0068] 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 product from slipping on the product support surface 32, as shown in Figure 9. Each friction point 290 is circular in shape, e.g., in the form of a raised protrusion. To reduce the weight and amount of material required to form the half size plastic pallet 20, the top deck 30 and pallet support legs 40 include a number of spaced apart openings 230, as described above.

[0069] Another aspect relates to a method for manufacturing a pallet 20 with grommets 250, as described above. The method includes forming a top deck 30 having a plurality of grommet openings 270 extending therein, each grommet opening 270 including a recessed shelf 272. A plurality of grommets 250 are inserted into the plurality of grommet openings 270. Each grommet 250 includes an upper section 253 including an upper lip 252 resting on the recessed shelf 272, and an outer exposed surface 254 of the upper section 253 extending above the top deck 30 at a height. At least one central section 258 is adjacent 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 includes a pair of spaced apart lower lips 263 extending from the at least one central section 258 and on the underside 34 of the top deck 30. An outer exposed surface 264 of the at least one lower section 260 extends at a height below the underside 34 of the upper deck 30. The method further includes forming a plurality of pallet support legs 40, coupling the plurality of pallet support legs 40 to the underside 34 of the upper deck 30, and forming an opening below the upper deck 30 for receiving a lift member.

[0070] 22 and 23, a half size plastic pallet 20 can be stacked with other identical half size plastic pallets 20. Grommets 250 adjacent the outer side 38 of the top deck 30 help hold the stacked half size plastic pallets 20 in place. This is accomplished by having a top surface 254 of the grommet 250 elevated above the upper product support surface 32 of the top deck 30. The raised top surface 254 of the grommet 250 above the product support surface 32 of the top deck 30 may range, for example, from 0.25 inches to 0.75 inches. This range is not intended to be limiting, as the actual raised top surface 254 may be outside of this range.

[0071] A pair of corresponding openings 300 are in the underside of the pallet support leg 40 for engaging the upper surfaces 254 of the grommets 250 in the stacked pallets 20, as shown by the cross-sectional view of the stacked half size plastics 20 in Figure 23. Each opening 300 is sized to receive the upper section 253 of the grommet 250, including not only the upper surface 254, but also a portion of the transition 256 between the upper surface 254 and the upper lip 252.

[0072] In particular, the pallet 20 includes an upper deck 30 including a product support surface 32 and an opposing lower surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, each of which includes a recessed shelf 272.

[0073] A plurality of grommets 250 are inserted into a plurality of grommet openings 270. Each grommet 250 includes an upper section 253 with an upper lip 252 that rests on a recessed shelf 272, with an outer exposed surface 254 of the upper section 253 extending vertically above the upper deck 30.

[0074] A plurality of pallet support legs 40 are on the underside 34 of the top deck and are aligned with a plurality of grommets 250 adjacent the outer side 38 of the top deck 30. Each pallet support leg 40 includes a base 42 extending across the width of the top deck 30 and a pair of outer base support elements 52. Each outer base support element 52 has a lower end integrally formed with an end of the base 42 and an upper end coupled to the underside 34 of the top deck 30. The lower surface of the base 42 is configured to engage the upper sections 253 of the pair of grommets 250 when identical pallets 20 are stacked.

[0075] The underside 34 of the base 42 includes a plurality of grommet openings 300, as shown in Figure 5. Each grommet opening 300 is configured to receive the upper section 253 of a respective grommet 250 of an identical pallet 20 when stacked thereon. With four grommet openings 300 provided in the base 42, the outer pallet support legs 40 can be coupled to the top deck 30 without being limited to being positioned adjacent a particular outer side 38 of the top deck 30.

[0076] The upper section 253 of each grommet 250 includes an upper surface 254 with a curved transition 256 between the upper surface 254 and the upper lip 252. The curved transition 256 acts as a guide for locating the upper surface 254 of the upper section 253 of the grommet 250 into a corresponding opening 300 in the base 42 of the pallet support leg 40. A plurality of grommet openings 270 are disposed on opposing outer sides 38 of the top deck 30, with each opposing outer side 38 having a pair of spaced apart grommet openings 270.

[0077] Another aspect relates to creating a pallet 20 that is stackable with other identical pallets 20, as described above. The method comprises forming a top deck 30 including a product support surface 32 and an opposing underside surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, each grommet opening 270 including a recessed shelf 272.

[0078] 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 including an upper lip 252 that rests on a recessed shelf 272. An outer exposed surface 254 of the upper section 253 extends to an elevation above the upper deck 30.

[0079] The method further includes forming a plurality of pallet support legs 40. Each pallet support leg 40 includes a base 42 extending across the width of the top deck 30, and a pair of outer base support elements 52. Each outer base support element 52 has a lower end integrally formed with an end of the base 42 and an upper end coupled to the underside 34 of the top deck 30. The underside of the base 42 is configured to engage the upper sections 253 of the pair of grommets 250 when identical pallets 20 are stacked. The plurality of support legs 40 are coupled to the underside 34 of the top deck 30, and the plurality of support legs 40 are aligned with the plurality of grommets 250.

[0080] Another feature of the top deck 30 is that it may be reconfigurable as a pallet / cart platform 30. A cart 400 is formed by adding cart wheels 402 to the reconfigurable pallet / cart platform 30 as shown in Figures 24-29. The reconfigurable pallet / cart platform 30 is advantageously reconfigured to support half size plastic pallets 20 or half size carts 400.

[0081] When the reconfigurable pallet / cart platform 30 is configured as a cart 400, the pallet support legs 40 are not coupled to the underside 34 of the platform 30. Similarly, when the reconfigurable pallet / cart platform 30 is configured as a pallet 20, the cart wheels 402 are not coupled to the underside 34 of the platform 30.

[0082] Returning to FIG. 11 , which shows the underside 34 of the top deck 30, a number of dolly wheel mounting areas 410 are provided for receiving a number of dolly wheels 402 when configured as a dolly 400. There are six dolly wheels 402 coupled to the underside 34 of the top deck 30, three on each side 36. Each dolly wheel mounting area 410 includes four attachment points 412 for securing the dolly wheels 402. Additional attachment points may be provided to receive a cover when the top deck 30 is being used as a pallet.

[0083] The product support surface 32 of the reconfigurable pallet / cart platform 30 is provided with a plurality of dolly wheel wells 420. The plurality of dolly wheel wells 420 are aligned with the plurality of dolly wheel receiving areas 410. Each dolly wheel well 420 is configured to engage a respective dolly wheel 402 from a same dolly 400 stacked thereon. Having the dolly wheel wells 420 receive dolly wheels 402 from the stacked dollies 400 provides stability when the stacked dollies 400 are moved.

[0084] Additionally, each dolly wheel well 420 may include a drain to prevent accumulation of water or other liquids. A dolly wheel 402 at one end of the dolly 400 may pivot about an axis perpendicular to the upper deck 30, while the other four dolly wheels 402 do not.

[0085] In particular, the reconfigurable pallet / cart platform 30 comprises an upper deck 30 including a product support surface 32 and an opposing underside surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, each grommet opening 270 including a recessed shelf 272.

[0086] The lower surface 34 includes a plurality of pallet support leg mounting areas 430, 432 that align with the plurality of grommet openings 270 and for receiving a plurality of pallet support legs 40 when configured as a pallet 20. The plurality of dolly wheel mounting areas 410 are for receiving a plurality of dolly wheels 402 when configured as a dolly 400.

[0087] The product support surface 32 includes a plurality of grommets 250 inserted into a plurality of grommet openings 270. Each grommet 270 includes an upper section 253 with an upper lip 252 that rests on a recessed shelf 272. An outer exposed surface 254 of the upper section 253 extends to an elevation above the upper deck and is configured to engage an underside 300 of a pallet support leg 40 from an identical platform 30 stacked thereon when configured as a pallet 20.

[0088] The multiple dolly wheel receiving areas 410 are aligned with the multiple dolly wheel storage sections 420 and are configured to engage with the multiple dolly wheels 402 of the same platform 30 stacked thereon when configured as a dolly 400.

[0089] The underside of each pallet support leg 40 includes a plurality of grommet openings 300, each configured to receive the upper section 254 of a respective grommet 250 of the same pallet 20 when stacked thereon.

[0090] Another embodiment relates to creating a reconfigurable pallet / cart platform 30, which includes forming an upper deck 30 including a product support surface 32 and an opposing underside surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, each grommet opening 270 including a recessed shelf 272.

[0091] The lower surface 34 includes a plurality of pallet support leg mounting areas 430, 432 that align with the plurality of grommet openings 270 and for receiving a plurality of pallet support legs 40 when configured as a pallet 20. The plurality of dolly wheel mounting areas 410 are for receiving a plurality of dolly wheels 402 when configured as a dolly 400.

[0092] The product support surface 32 includes a plurality of grommets 250 inserted into a plurality of grommet openings 270. Each grommet 270 includes an upper section 253 with an upper lip 252 that rests on a recessed shelf 272. An outer exposed surface 254 of the upper section 253 extends to an elevation above the upper deck and is configured to engage an underside 300 of a pallet support leg 40 from an identical platform 30 stacked thereon when configured as a pallet 20.

[0093] The multiple dolly wheel receiving areas 410 are aligned with the multiple dolly wheel storage sections 420 and are configured to engage with the multiple dolly wheels 402 of the same platform 30 stacked thereon when configured as a dolly 400.

[0094] Many modifications and other embodiments of the invention 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, and it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A pallet comprising: an upper deck having a plurality of grommet openings extending therethrough, each grommet opening including a recessed shelf and a partition below the recessed shelf; A plurality of grommets inserted into the plurality of grommet openings; an upper section including an upper lip resting on the recessed shelf, an outer exposed surface of the upper section extending at an elevation above the upper deck; a pair of central sections extending from the upper deck to a lower surface of the upper deck, each central section being separated by the partition, a portion of the pair of central sections having an opening to accommodate the partition; a pair of lower sections extending from the pair of central sections, each lower section including a pair of spaced apart lower lips on the underside of the upper deck, an outer exposed surface of each lower section extending at a height below the underside of the upper deck; a plurality of grommets each comprising: A pallet comprising:

2. 2. The pallet of claim 1, wherein the divider includes a lower surface flush with a lower surface of the top deck.

3. 2. The pallet of claim 1, wherein said divider includes an upper surface underlying said recessed shelf.

4. 2. The pallet of claim 1, wherein said plurality of grommet openings are disposed adjacent a periphery of said top deck.

5. 2. The pallet of claim 1, wherein each grommet opening and each grommet is rectangular.

6. 2. The pallet of claim 1, wherein each grommet comprises at least one of natural rubber and synthetic rubber.

7. 2. The pallet of claim 1, wherein the top deck comprises plastic.

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