Half-size plastic pallet with grommet on the upper deck

Abstract

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 the 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, the outer exposed surface of the upper section extending at a height 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. At least one lower section includes a pair of spaced-apart lower lips that extend from the at least one central section and rest on the underside of the upper deck. The outer exposed surface of the at least one lower section extends at a height lower than the underside of the upper deck.

Description

Technical Field

[0001] The present disclosure relates to the field of pallets, and more particularly to half-size plastic pallets.

Background Art

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

[0003] Retail stores often prefer to use split pallets when displaying products for customers to purchase. Split pallets are typically sized from one-quarter to one-half of a full-size pallet. The footprint of a split pallet is quite small, allowing a retail store to display a variety of products within an area the same size as a full-size pallet.

[0004] Furthermore, retail stores often prefer to use plastic split pallets rather than wooden split pallets. Plastic split pallets are more aesthetically pleasing and hygienic than wooden split pallets.

[0005] Even considering current split plastic pallets, there is still a need for split plastic pallets that can be easily moved by pallet handling equipment and that allow for aesthetically acceptable product displays. Since the products carried on split plastic pallets can be relatively heavy, access should not be sacrificed at the expense of the pallet's load-bearing capacity.

Summary of the Invention

Means for Solving the Problems

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

[0007] Each grommet opening can further include a partition, and at least one central section may include a pair of spaced central sections. Each central section is separated by a partition. At least one lower section includes a pair of lower sections, each lower section extending from its respective central section.

[0008] The partition may include the lower surface or the lower surface of the upper deck. The partition may include an upper surface under the recessed shelf.

[0009] The openings of the grommets are arranged adjacent to the periphery of the upper deck. Each grommet opening and each grommet are rectangular.

[0010] Each grommet may include at least one of natural rubber and synthetic rubber. The upper deck and the pallet support legs may be made of plastic.

[0011] Another aspect is directed to a method for manufacturing a pallet as described above having grommets on an upper deck. The pallet includes an upper deck having grommet openings extending therethrough, each grommet opening including a recessed shelf. The grommets are inserted into the grommet openings. Each grommet includes an upper section having an upper lip resting on the recessed shelf, the outer exposed surface of the upper section extending at a height above the upper deck. At least one central section is adjacent to the upper lip and extends from the upper section to the lower surface of the upper deck. At least one lower section extends from at least one central section and includes a pair of spaced lower lips resting on the lower side surface of the upper deck. The outer exposed surface of at least one lower section extends at a height lower than the lower side surface of the upper deck. The method further includes forming pallet support legs, coupling the pallet support legs to the lower side surface of the upper deck, and forming an opening under the upper deck for receiving a lift member.

Brief Description of the Drawings

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[0013] The description will be made with reference to the accompanying drawings showing exemplary embodiments. However, many different embodiments may be used, and thus the description should not be construed as being limited to the specific embodiments described herein. These embodiments are rather provided so that the present disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0014] First, refer to FIGS. 1 and 2. First, referring to FIGS. 1 and 2, the illustrated half-size plastic pallet 20 includes an upper deck 30 and three removable pallet support legs 40 coupled to the upper deck. The pallet support legs 40 are removable from the upper deck 30, whereby a half-size plastic pallet can be easily repaired if the pallet support legs 40 or the upper deck 30 are damaged.

[0015] The three pallet support legs 40 include a pair of outer pallet support legs and a central pallet support leg. The pallet support legs 40 are configured to allow four-directional access by pallet handling equipment such as a forklift or a pallet jack. As will be described in detail below, the plastic pallet 20 is repairable, stackable, and includes mounting positions 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 can be used with plastic pallets of other sizes. The size of the plastic pallet 20 can be, for example, 24 inches by 20 inches and can be reduced to a quarter size. The size of the plastic pallet 20 can also be 48 inches by 40 inches and can be enlarged to a full size. These dimensions can be adjusted to accommodate countries that use the metric system.

[0017] The upper deck 30 includes an upper surface called the product support surface 32 and an opposite lower surface called the lower surface 34. The upper deck 30 has an outer exposed surface that extends between the product support surface 32 and the lower surface 34 on the opposite side. The outer exposed side surfaces include spaced-apart outer side surfaces 36 and spaced-apart outer side surfaces 38. The outer side surface 36 corresponds to the length of the half-size plastic pallet 20, and the outer side surface 38 corresponds to the width or end of the half-size plastic pallet 20. The length is a dimension longer than the dimension of the half-size plastic pallet 20 (i.e., 40 inches), while the width is a dimension shorter than the dimension of the half-size plastic pallet 20 (i.e., 24 inches).

[0018] The outer pallet support legs 40 are aligned in a straight line with the outer side surface 38. That is, the outer side surface 38 is parallel to the pallet support legs 40. Each pallet support leg 40 has the same length as the dimension of the outer side surface 38. That is, each pallet support leg 40 extends across the width of the half-size plastic pallet 20.

[0019] Referring now to FIGS. 3-6, each pallet support leg 40 includes a base 42 and base support elements 52, 72 extending from the base 42. The base support elements 52, 72 are coupled to the lower surface 34 of the upper 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 integrally formed with the base 42 and an exposed upper end. A pair of outwardly extending snaps 54 extend from the exposed upper end and contact the lower surface 34 of the upper deck 20. Similarly, a pair of inwardly extending snaps 56 extend from the exposed upper end and contact the lower surface 34 of the upper deck 20. The snaps 54, 56 are configured to engage with snap openings 170 in the lower surface 34 of the upper deck 30, thereby coupling the outer base support element 52 to the upper deck 30.

[0021] The lower surface 34 of the upper deck 30 further has a plurality of guide openings 172 adjacent to the plurality of snap openings 170. Extending from the exposed upper end of the outer base support element 52 is also a pair of spaced 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 or contour of the outer base support element 52 defined by the outward sidewall 51, the inward sidewall 53, and the pair of curved end walls 55. The dimensions of the guide openings 172 in the lower surface 34 of the upper deck 30 are smaller than the dimensions of the profile or contour of the outer base support element 52 to receive the guides 58.

[0022] As shown in FIG. 10, the snap openings 170 for the outward snaps 54 are oriented outwardly to be exposed through the outer side surface 36 of the upper deck 30, while the snap openings 170 for the inward snaps 56 are inward and not exposed. The height of the guides 58 may be the same as the height of the snaps 54, 56. In other embodiments, the height of the guides 58 may be different from the height of the snaps 54, 56.

[0023] The outer base support element 52 has an outward sidewall 51 from which a pair of outward snaps 54 extend, and a spaced inward sidewall 53 from which a pair of inward snaps 56 extend. The pair of outward snaps 54 are recessed from the outward sidewall 51. The pair of inward snaps 56 are recessed from the inward sidewall 53.

[0024] The pair of curved end walls 55 are at the ends of the outward and inward sidewalls 51 and 53, and the pair of guides 58 extend from the pair of curved end walls 55. A portion of each guide 58 is curved corresponding to the curvature of the curved end wall 55. The pair of guides 58 are recessed from the pair of curved end walls 55.

[0025] Each of the snaps 54, 56 includes a flexible snap element 60, a lip 62 extending outwardly from the snap element 60, and an inclined surface or edge 64 between the lip 62 and the snap element 60. The inclined surface 64 and the lip 62 engage bendably with corresponding snap openings 170 in the lower surface 34 of the upper deck 30.

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

[0027] The lower surface 34 of the upper deck 30 further has a plurality of guide openings 182 adjacent to the plurality of snap openings 180. Also extending from the exposed upper end of the central base support element 72 are two pairs of spaced guides 78. The guides 78 are configured to align the snaps 74 with the snap openings 180 in the lower surface 34 of the upper deck 30. The guide openings 182 correspond to the profile or contour of the central base support element 72 defined by the wall 73. The dimensions of the guide openings 182 in the lower surface 34 of the upper deck 30 are smaller than the dimensions of the profile or contour of the central base support element 72 to receive the guides 78.

[0028] The central base support element 72 is circular. The two pairs of snaps 74 extend from a circular wall 73, and the guides 78 and the snaps 74 extend back from the circular wall 73. The guides 78 and the snaps 74 are curved to conform to 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 an inclined surface or edge 84 between the lip 82 and the snap element 80. The inclined surface 84 and the lip 82 engage flexibly with corresponding snap openings 180 in the lower surface 34 of the upper deck 30.

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

[0031] Each pallet support leg 40 is identical to each other. The base 42 of each pallet support leg 40 includes an opening 44 for receiving a reinforcing bar. The reinforcing bar increases the strength and durability of the pallet support leg 40. The reinforcing bar can be, for example, steel or metal, but is not limited thereto. The base 42 includes spaced 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 hold the reinforcing bar therein. The opening 44 may be sized to receive, for example, a 1 / 2 inch or 5 / 8 inch plug 45.

[0032] Each pallet support leg 40 may be formed of a thermoplastic or polymeric material. Similarly, the upper deck 30 may also be formed of a thermoplastic or polymeric material. The plastic used for 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 an upper deck 30 having a product support surface 32 and an opposite lower surface 34, the lower 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 extending across the width of the upper deck 30 and a pair of outer base support elements 52. Each outer base support element 52 has a lower end formed integrally with the base 42 and an exposed upper end. A pair of outward snaps 54 extend from the exposed upper end of each outer base support element 52 and contact the lower surface 34 of the upper deck 30. A pair of inward snaps 56 extend from the exposed upper end of each outer base support element 52 and contact the lower surface 34 of the upper deck 30. The method further includes engaging the pair of outward and inward snaps 54, 56 with respective snap openings 170 in the lower surface 34 of the upper deck 30 to couple the pallet support legs 40 to the upper deck 30.

[0034] Next, the upper deck 30 will be described in more detail with reference to FIGS. 7 - 9. The upper deck 30 is formed as a unitary body and includes four quadrants 100(1) - 100(4). Each quadrant may generally be referred to as quadrant 100. The quadrants 100 are of a symmetric design except for shrink wrap gripping members 110 in quadrants 100(1) and 100(3) only.

[0035] The shrink wrap gripping members 110 are used to cover and hold a shrink wrap on a product carried by the upper deck 30. The shrink wrap is generally used to secure the product to the pallet. This is often an alternative to strapping, although both can be applied if desired.

[0036] The problem that occurs when using shrink wrap on a pallet is to fix the edge of the shrink wrap. This problem is faced both at the start and end of shrink wrapping, because there may be cases where the wrap does not want to adhere to the product or pallet, or ultimately where the wrap cannot be fastened to the pallet's product.

[0037] The shrink wrap gripping member 110 is arranged along the side surface 36 of the upper deck 30. There is one shrink wrap gripping member 110 on each side surface 36, that is, in quadrants 100(1) and 100(3). In other embodiments, quadrants 100(2) and 100(4) also include shrink wrap gripping members 110, and all of the quadrants 100 may be a design that is targeted.

[0038] Each shrink wrap gripping member 110 has 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, and there is a narrow opening between them. Due to the narrowing of the opening, the shrink wrap can be placed in the groove, making it difficult for the wrap to come out of the groove again. The wrap can be pulled into the front or rear recess, and the edge of the wrap can be fixed at the start or end of the wrapping process.

[0039] Another feature of the upper deck 30 is that it includes grooves 150 for use as positioning for the binding straps. A pair of grooves 150 are arranged on each of the longer side surfaces 36 of the upper deck 30.

[0040] Each quadrant 100 includes a hand access hole 102. The hand access hole 102 provides an easy means for an operator to handle the half-size plastic pallet 20. The hand access hole 102 is large enough for the user to insert all four fingers into it. By providing the hand access hole 102 in each quadrant 100, the half-size plastic pallet 20 can be very easily gripped by the user for carrying it or lowering it from a stacked pallet.

[0041] The upper deck 30 includes several different product display attachment positions for securing a product display or box to the half - size plastic pallet 20. When the half - size plastic pallet 20 is placed on the floor of a store, for example, with products on it, the product display serves to promote the products. U.S. Patent No. 9,387,953 discloses a partial plastic pallet with product display attachment positions, which is hereby incorporated by reference in its entirety. U.S. Patent No. 9,387,953 is assigned to the current assignee of the present invention.

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

[0043] A pair of display attachment slots 120 are disposed adjacent to each side surface 36, 38 of the upper deck 30, for a total of eight display attachment slots 120. There are also eight display attachment slots 130 and eight display attachment slots 150 on the product support surface 32. Each display attachment slot 130 is aligned with a respective display attachment slot 120, and each display attachment slot 150 is recessed from the side surfaces 36, 38 of the upper deck 30 and is also aligned with a respective display attachment slot 130.

[0044] Referring further to FIG. 9, each display mounting slot 130 includes an outer slot 132 within the upper deck 30 and an inner slot 138 that is recessed within the outer slot. The outer slot 132 includes a side surface 134 and a partially closed bottom 136 that forms a curved shelf. The inner slot 138 is adjacent to the curved shelf 136 and is recessed below the outer slot 132. The inner slot 138 has a pair of spaced side walls 140 and 142 and a closed bottom 144.

[0045] Within the inner slot 132, the side wall 140 includes a protrusion 145 extending therefrom, and the opposing side wall 142 includes a tapered member 146 extending therefrom. The tapered member 146 has a downward taper toward the protrusion 145. When the product display tab has a hole appropriately positioned, the hole can engage and be fixed to the protrusion 145 or the tapered member 146.

[0046] The side wall 142 with the tapered member 146 is curved corresponding to the curved shelf 136, while the side wall 140 with the protrusion 145 is not curved. The tapered member 146 includes a lowermost surface 148 that is perpendicular to the closed bottom 144 of the inner slot 138. There is a gap between the flat lower side 148 and the closed bottom 144. The protrusion 145 has, for example, a quarter-spherical shape. The tapered member 146 is aligned with the center of the protrusion 145.

[0047] Each display mounting slot 150 is recessed from the side surfaces 36, 38 of the upper deck 30. A substantial portion of the corresponding side surfaces 36, 38 of the upper deck 30 is removed to expose the display mounting slot 150. The removal of the corresponding side surfaces 36, 38 of the display mounting slot 150 is uniform to form a pair of spaced retaining tabs 151 for fixing the product display tab. The retaining tabs 151 are at the upper part of the display mounting slot 150, while the lower part of the display mounting slot 150 is fully exposed.

[0048] The upper 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 upper deck 30. The reinforcing bars may be, for example, steel or metal, but are not limited thereto. The side 38 has three openings 160 for receiving the reinforcing bars, and the side 36 has two openings 162. After the reinforcing bars are inserted into the openings 160, 162, a plug 45 as shown in FIG. 6 is inserted into the openings 160, 162 to hold the reinforcing bars. The openings 160, 162 may be sized to receive a plug 45 of, for example, 1 / 2 inch or 5 / 8 inch.

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

[0050] The snap 74 associated with the central base support element 72 is fixed to a corresponding snap opening 180 exposed on the lower side surface 34 of the upper deck 30. Similarly, the snaps 54, 56 associated with the outer base support element 50 are fixed to corresponding snap openings 170 exposed on the lower side surface 34 of the upper deck 30. The outer snap pin 52 can be seen from the side surface 36 of the upper deck 30.

[0051] The product support surface 32 of the upper deck 30 includes an opening for receiving a jig used to remove the pallet support legs 40. The jig contacts all of the snaps 54, 56, 74 on the pallet support legs 40 and enables them to be snap-released from the lower side surface 34 of the upper deck 30.

[0052] Here, with reference to FIGS. 10 to 12, the four substantially symmetric quadrants 100 will be described in more detail. Each quadrant 100 includes a pair of spherical curvatures 200, 210. The spherical curvatures 200, 210 may also be referred to as deck scoop regions. The spherical curvatures 200, 210 each reduce the thickness of the upper deck 30 within each quadrant 100. The spherical curvatures 200, 210 advantageously reduce the influence of the deflection of the central quadrant on the fork tine capacity to pass through the opening under the upper deck 30. When the load on the half-size pallet 20 is large, deflection may occur in the central quadrant.

[0053] In other embodiments, each quadrant 100 may include a single spherical curvature such as the spherical curvature 200 or 210. In still other embodiments, the single spherical curvature may partially overlap between the spherical curvatures 200 or 210.

[0054] The spherical curvature 200 may be referred to as the first deck scoop region, and the spherical curvature 210 may be referred to as the second deck scoop region. The second deck scoop region 210 is larger in size than the first deck scoop region 200. The first deck scoop region 200 has a rectangular shape, and the second deck scoop region 210 has a square shape.

[0055] The lower surface 34 of the upper deck 30 is composed of exposed ribs. The first deck scoop region 200 includes respective hand access holes 102. The hand access holes 102 are at the center within the first deck scoop region 200. The hand access holes 102 are at the apex of the curvature of the first deck scoop region 200. This apex corresponds to the point of the minimum thickness of the upper deck 30 within the first deck scoop region 200.

[0056] The hand access hole 102 includes a wall 103 that extends from the product support surface 32 to the lower surface 34 on the opposite side of the upper deck 30. The exposed rib 202 extends in a first direction, and the exposed rib 204 extends in a second direction orthogonal to the first direction within the first deck scoop region 200.

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

[0058] The second deck scoop region 210 is separated from the first spherical curving 200 by a transition wall 220. The thickness of the upper deck 30 does not become thinner at the transition wall 220. The ribs within the second deck scoop region 210 include a rib 212 that extends in a first direction and a rib 214 that extends in a second direction orthogonal to the first direction.

[0059] The second deck scoop region 210 includes a plurality of spaced-apart openings 230 in each quadrant 100, as shown in FIG. 8. The openings 230 extend to the lower surface 34 of the upper deck 30. The openings 230 may be divided into grid-like, spaced-apart opening sections. Each opening section has a pattern of openings 230 that is symmetric with respect to each of the other opening sections within each second deck scoop region 210.

[0060] Another aspect relates to a method for manufacturing a pallet 20 having the deck scoop regions 200, 210 described above. The method includes forming an upper deck 30 divided into quadrants 100 and forming a plurality of pallet support legs 40. The pallet support legs 40 are coupled to the lower surface 34 of the upper deck 30 and form an opening under the upper deck 30 for receiving a lift member. The upper deck 30 is formed to include at least one deck scoop region 200, 210 in the lower surface 34 in each quadrant 100. The thickness of the upper deck 30 is thinned at each deck scoop region 200, 210 to reduce the effect of deflection of the upper deck on the passage of the lift member through the opening under the upper deck 30.

[0061] The upper deck 30 may be further configured with provisions for enabling the attachment of an electronic tracking device. The compartment may be formed or attached to the lower surface 34 of the upper deck 30, for example, to carry the electronic tracking device. Fasteners may use 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, but is not limited to, communication protocols such as Bluetooth, Bluetooth Low Energy (BLE), RFID, cellular, GPS, etc.

[0062] Now, with reference to FIGS. 13-21, the use of grommets 250 within the upper deck 30 will be described. The grommets 250 advantageously provide a preferred grip when disposed on the product support surface 32 of the upper deck 30 and provide a preferred grip for forklift claws on the lower surface 34 of the upper deck 30. The grommets 250 also advantageously serve to hold the same half-size plastic pallet 20 in a predetermined position when stacked on another half-size plastic pallet 20. Materials suitable for the grommets 250 include, for example, natural rubber and synthetic rubber.

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

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

[0065] Below the recessed shelf, the opening 270 has a second peripheral size that is smaller than the first peripheral size. Contained within the second peripheral size is a partition 274. The upper surface of the partition 274 is recessed from the recessed shelf 272, and the lower surface of the partition 274 continues with the lower side surface 34 of the upper deck 30. The partition 274 requires that the lower portion of each grommet 250 have an opening or gap 259 for receiving the partition 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. The upper surface 254 of each grommet 250 is flat and rises above the product support surface 32 of the upper deck 30. The 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 extends from the upper section 253 of each grommet 250. The central sections 258 are on the adjacent sides of the partition 274. Each lower section 260 extends from each central section 258. The lower section 260 extends to the lower surface 34 of the upper deck 30 and flares out to engage the lower surface 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 lower surface 34 of the upper deck 30.

[0068] In addition to the grommets 250, the product support surface 32 of the upper deck 30 includes an array of friction points 290 for preventing the sliding of products on the product support surface 32 as shown in FIG. 9. Each friction point 290 has a circular shape and is, for example, 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 upper deck 30 and the pallet support legs 40 include several 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 an upper 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 upper deck 30 in height. At least one central section 258 is adjacent to the upper lip 252 and extends from the upper section 253 to the lower surface 34 of the upper deck 30. At least one lower section 260 extends from at least one central section 258 and includes a pair of spaced lower lips 263 on the lower surface 34 of the upper deck 30. The outer exposed surface 264 of at least one lower section 260 extends at a height below the lower surface 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 lower surface 34 of the upper deck 30, and forming an opening for receiving a lift member under the upper deck 30.

[0070] Referring now to FIGS. 22 and 23, the half-size plastic pallet 20 is stackable with other identical half-size plastic pallets 20. The grommets 250 adjacent to the outer side surface 38 of the upper deck 30 help hold the stacked half-size plastic pallets 20 in place. This is achieved by the upper surface 254 of the grommet 250 being higher than the upper product support surface 32 of the upper deck 30. The raised upper surface 254 of the grommet 250 above the product support surface 32 of the upper deck 30 may range, for example, from 0.25 inches to 0.75 inches. This range is not limiting as the actual raised upper surface 254 may take on values outside of this range.

[0071] A pair of corresponding openings 300 are on the lower surface of the pallet support legs 40 to engage with the upper surface 254 of the grommet 250 in the stacked pallets 20, as shown by the cross-sectional view of the half-size plastic 20 stacked in FIG. 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 part of the transition portion 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 opposite lower surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes a recessed shelf 272.

[0073] A plurality of grommets 250 are inserted into the plurality of grommet openings 270. Each grommet 250 includes an upper section 253 having an upper lip 252 that rests on the recessed shelf 272, and the outer exposed surface 254 of the upper section 253 extends in the height direction higher than the upper deck 30.

[0074] A plurality of pallet support legs 40 are on the lower surface 34 of the upper deck and are aligned with a plurality of grommets 250 adjacent to the outer side surface 38 of the upper deck 30. Each pallet support leg 40 includes a base 42 extending across the width direction of the upper 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 lower surface 34 of the upper deck 30. The lower surface of the base 42 is configured to engage with the upper sections 253 of a pair of grommets 250 when the same pallets 20 are stacked.

[0075] As shown in FIG. 5, the lower surface 34 of the base 42 includes a plurality of grommet openings 300. Each grommet opening 300 is configured to receive the upper section 253 of each grommet 250 of the same pallet 20 when stacked thereon. Since there are four grommet openings 300 provided in the base 42, the outer pallet support legs 40 can be coupled to the upper deck 30 without being limited to an arrangement adjacent to a specific outer side surface 38 of the upper deck 30.

[0076] The upper section 253 of each grommet 250 includes an upper surface 254, and the transition portion 256 between the upper surface 254 and the upper lip 252 is curved. The curved transition portion 256 functions as a guide for positioning the upper surface 254 of the upper section 253 of the grommet 250 in the corresponding opening 300 in the base 42 of the pallet support leg 40. A plurality of grommet openings 270 are disposed on opposite outer side surfaces 38 of the upper deck 30, and each opposite outer side surface 38 has a pair of spaced-apart grommet openings 270.

[0077] Another aspect relates to creating a pallet 20 stackable with other identical pallets 20 as described above. The method comprises forming an upper deck 30 including a product support surface 32 and an opposite lower surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes 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 having an upper lip 252 on the recessed shelf 272. The outer exposed surface 254 of the upper section 253 extends to a height 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 direction of the upper 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 lower surface 34 of the upper deck 30. The lower side of the base 42 is configured to engage the upper section 253 of a pair of grommets 250 when the same pallets 20 are stacked. The plurality of support legs 40 are coupled to the lower surface 34 of the upper deck 30, and the plurality of support legs 40 are aligned with the plurality of grommets 250.

[0080] Another feature of the upper deck 30 is that it may be reconfigurable as a pallet / cart platform 30. The cart 400 is formed by adding cart wheels 402 to the reconfigurable pallet / cart platform 30 as shown in FIGS. 24-29. The reconfigurable pallet / cart platform 30 is advantageously reconfigured to support a half-size plastic pallet 20 or a half-size cart 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 lower surface 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 lower surface 34 of the platform 30.

[0082] Returning to FIG. 11 showing the lower surface 34 of the upper deck 30, a plurality of bogie wheel mounting areas 410 are provided for receiving a plurality of bogie wheels 402 when configured as a bogie 400. There are six bogie wheels 402 coupled to the lower surface 34 of the upper deck 30, three on each side surface 36. Each bogie wheel mounting area 410 includes four attachment points 412 for fixing the bogie wheels 402. When the upper deck 30 is used as a pallet, additional attachment points may be provided for receiving a cover.

[0083] On the product support surface 32 of the reconfigurable pallet / bogie platform 30, a plurality of bogie wheel storage portions 420 are provided. The plurality of bogie wheel storage portions 420 are aligned with the plurality of bogie wheel receiving areas 410. Each bogie wheel storage portion 420 is configured to engage each bogie wheel 402 from the same bogie 400 stacked thereon. By having the bogie wheel storage portions 420 that receive the bogie wheels 402 from the stacked bogies 400, stability is provided when the stacked bogies 400 are moved.

[0084] Furthermore, each bogie wheel storage portion 420 may be provided with a drain opening so that water or other liquids do not accumulate. The bogie wheel 402 at one end of the bogie 400 can pivot about an axis perpendicular to the upper deck 30, while the other four bogie wheels 402 do not pivot.

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

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

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

[0088] The plurality of cart wheel receiving regions 410 are aligned with the plurality of cart wheel storage portions 420 and are configured to engage the plurality of cart wheels 402 of the same platform 30 stacked thereon when configured as the cart 400.

[0089] Below each pallet support leg 40, a plurality of grommet openings 300 are included, and each grommet opening 300 is configured to receive the upper section 254 of each grommet 250 of the same pallet 20 when stacked thereon.

[0090] Another aspect relates to fabricating a reconfigurable pallet / cart platform 30 that includes forming an upper deck 30 that includes the product support surface 32 and the opposite lower surface 34. The product support surface 32 has a plurality of grommet openings 270 extending therethrough, and each grommet opening 270 includes a recessed shelf 272.

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

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

[0093] The plurality of cart wheel receiving regions 410 are aligned with the plurality of cart wheel storage portions 420 and are configured to engage the plurality of cart wheels 402 of the same platform 30 stacked thereon when configured as the cart 400.

[0094] Many modifications of the present invention and other embodiments will be apparent to those of ordinary skill in the art having the benefit of the teachings presented in the foregoing description and the related drawings. Therefore, it is to be 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 through the upper deck, each grommet opening including a recessed shelf and a partition; a plurality of pallet support legs coupled to a lower surface of the upper deck; a plurality of grommets inserted into the plurality of grommet openings, an upper section having an upper lip resting on the recessed shelf, an outer exposed surface of the upper section extending at a height above the upper deck, and an upper section; one central section adjacent to the upper lip and extending from the upper section to a lower side of the upper deck, a part of the one central section having a gap for accommodating the partition, and one central section; at least one lower section extending from the one central section, each of the at least one lower section including a lower lip spaced apart through a gap located below the lower side of the upper deck, and an outer exposed surface of the at least one lower section extending in a height direction higher than a lower side of the upper deck, and at least one lower section; a plurality of grommets; A pallet characterized by comprising the above.

2. The pallet according to claim 1, wherein the one central section consists of a central section spaced apart through a gap, each central section being separated by the partition, and the at least one lower section consists of a pair of lower parts, each lower part extending from a respective central section.

3. The pallet according to claim 1, wherein the partition includes a lower surface at the same height as a lower surface of the upper deck.

4. The pallet according to claim 1, wherein the partition includes an upper surface located below the recessed shelf.

5. The pallet according to claim 1, wherein the plurality of grommet openings are arranged adjacent to a periphery of the upper deck.

6. The pallet according to claim 1, wherein each grommet opening and each grommet are rectangular.

7. The pallet according to claim 1, wherein each grommet includes at least one of natural rubber and synthetic rubber.

8. The pallet according to claim 1, wherein the upper deck and the plurality of pallet support legs include plastic.

9. A method for manufacturing a pallet, comprising: forming an upper deck having a plurality of grommet openings extending therethrough, the upper deck forming a recessed shelf and partition for each grommet opening; inserting a plurality of grommets into the plurality of grommet openings; an upper section having an upper lip resting on the recessed shelf, the outer exposed surface of the upper section extending at a height above the upper deck, and an upper section; one central section extending from the upper section to the lower surface of the upper deck, a part of the one central section having a gap for receiving the partition, and one central section; at least one lower section extending from the one central section, including a lower lip spaced apart through a gap located on the lower surface of the upper deck, the outer exposed surface of the at least one lower section extending in the height direction above the lower surface of the upper deck, and at least one lower section; inserting a plurality of grommets into the plurality of grommet openings provided; forming a plurality of pallet support legs; coupling the plurality of pallet support legs to the lower surface of the upper deck and forming the opening under the upper deck for receiving a lift member; A method for manufacturing a pallet including the above.

10. The method according to claim 9, wherein the one central section includes a pair of central sections arranged at intervals, each central section being separated by the partition, and the at least one lower section includes a pair of lower sections, each lower section extending from the central section.

11. The method according to claim 10, wherein the partition includes a lower surface at the same height as the lower surface of the upper deck.

12. The method according to claim 9, wherein the plurality of grommet openings are arranged adjacent to the periphery of the upper deck.

13. The method according to claim 9, wherein each grommet opening and each grommet are rectangular.

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