MXPA01000202A - Pallet assembly - Google Patents

Abstract

A pallet assembly (10) includes a top deck (14) formed of plastic which has a first opposing surface having a plurality of first flanged portions (34) projecting downwardly therefrom. The top deck (14) has a substantially planar upper surface upon which a plurality of objects are capable of resting. The pallet assembly (10) also includes a bottom deck (12) which is also formed of plastic and a second opposing surface with a plurality of second flanged portions (36) projecting therefrom in an upward direction. The plurality of second flanged portions correspond to and securely mate with the plurality of flanged portions to define a plurality of columns (20) between the top and bottom decks, the columns having a box beam cross section for providing strength to the pallet assembly. The top deck (14) includes a top member (30) and a mid-top member (40), and the bottom deck (12) includes a bottom member (42) and a mid-bottom member (44).

Description

PALLET ASSEMBLY TECHNICAL FIELD This invention is concerned with a set or assembly of plastic pallet for storing or transporting goods.

BACKGROUND OF THE INVENTION The pallets used in the industry today are more commonly formed of slats and crosspieces or blocks of wood that are nailed together. While such pallets are functional, they have many disadvantages. First, wooden pallets are relatively heavy. Second, the wood is not easily cleaned because it absorbs water and other liquids that damage and ripple the wood. For these same reasons, the use of wooden pallets outside or in humid environments is also limited. Frequently the wooden pallets are not dimensioned consistently due to size variations in the wooden slats and the shrinkage of the wood over time, thus preventing such pallets from being stacked or stored in a stable or consistent manner. In addition, the nails used to hold the wooden pallets together can cause damage to the goods that are stored and transported in the pallet or can splinter over time. Also, once the Ref: 126386 wooden pallets are damaged, have little or no residual value and also need rights or quotas for their disposal. The replacement of wooden pallets with plastic pallets has been a goal for many years. The advantages of plastic pallets are many compared to wood, which include greater durability, lighter weight, more consistent dimensions, improved cleaning, water resistance, higher residual value for recycling and also no nail that It could damage the products that are supported on them. While many plastic pallets have been tried, designs that are apt to approximate the strength of the wood, to date, have been prohibitive in cost and may not have the required strength properties. For example, plastic vanes having a solid section, while having favorable rigidity and bending properties, are heavy and use a relatively large amount of material in their formation. The wood is five to eight times more rigid than a typical plastic used to make pallets. The plastic pallets must either use much more material, to be taller or have reinforcements such as steel rods or fillers or glass reinforcements to compensate for this difference. While conventional plastic pallets have ribbed supports to decrease their weight, they often lack the rigidity and low yield properties of the solid pallet and in order to improve these properties, the pallet height must be increased or they should add reinforcements to the plastic such as reinforcements of steel and other compounds. Of course, these additions to the plastic cause an increase in the density of the material leading to an even heavier pallet. In addition, the design resins are very expensive, resulting in a more expensive palette. Another obstacle to overcome with plastic is cost. Plastic pallets are more expensive than wood for three to five times. This cost can be offset by the number of trips or shipments that can be obtained with plastic pallets against wooden pallets. Another main obstacle is the rigidity of the plastic pallets. Storage of pallets loaded in warehouses for up to 30 days may be common and the combination of low tensile strength and gradual yield may limit the use of plastic in this way. There are three conventional methods to overcome these disadvantages. The first is to add reinforcement such as steel or a compound to the pallet. This adds significantly to the cost and weight and complicates the recycling of the pallet. The second is to manufacture the highest palette. This generally limits the height of a product that is going to be stacked on the pallet, also as the number of pallets that can be stored in a given area. The third is to use reinforced or design resins. Again, this adds significant cost and weight. All three obviously limit the acceptance of plastic pallets. U.S. Patent No. 3,580,190 provides a partial solution to the problem of stiffening by joining upper and lower sheets 22, 24 to the structural network 23, as shown in Figure 1 thereof. However, this solution does not solve the problem of bending stiffness or curvature because there are still large lateral and longitudinal unsupported areas, such as in areas 26, 37, 38, 49 and 50. In other words, this design only stiffens support column areas 67, 68, 69, 97, 98, 99, 28, 30, 32, which already provide substantial rigidity only as a result of their height. The weakness of this design is evident in column 6, lines 60-71, where the reference recommends the use of a material that has a flexural modulus (or Young's modulus) greater than about 14.060 Kg / square centimeter (200,000 pounds) / square inch). Such a high modulus material is obviously required because the structure described does not provide significant resistance to bending along the length and width of the pallet. A high modulus material adds substantial cost to the pallet.

In addition, the pallets commonly require large openings for receiving pallet receptacles or sockets (jacks). Due to these large openings, the structure of the vane is normally thin and weak and has poor flexural rigidity. Because the pallets are exposed to significant abuse, any solution to the stiffness problem should not adversely affect the impact strength of the pallet. Consequently, an improved palette that should be reasonably non-expensive, lightweight and robust is desirable. The improved palette should also have improved rigidity and gradual yield properties. The pallet must also be able to withstand various environmental conditions to which it may be exposed, particularly moisture. The improved palette should also be easy to store, have a size compatible with a standard wood pallet and be reusable. Also, there is a need to improve the rigidity of plastic pallets configured to receive a socket or pallet receptacle, without reducing the impact resistance of the pallet. The improved pallet design should also be applied to components used in association with the pallets.

BRIEF DESCRIPTION OF THE INVENTION It is a principal object according to the present invention to provide an improved pallet assembly or assembly that is relatively lightweight, not expensive to be manufactured and assembled and dimensioned consistently. It is another object in accordance with the present invention to provide an improved pallet assembly or assembly having desirable properties of strength, stiffness, gradual yield and bending. It is another object in accordance with the present invention to provide an improved blade assembly or assembly that is capable of withstanding varied environmental conditions, particularly moisture with little damage or wear and which is easily reusable. It is still another object in accordance with the present invention to provide an improved vane assembly that can be stored, stowed or stacked in a stable manner. Another object of the present invention is to provide a method for structurally reinforcing a plastic vane configured to receive a vane plug or receptacle, in a manner that provides rigidity without loss of impact resistance. It is yet another object to provide a highly rigid pallet without the use of reinforcement or design resins that increase the cost and weight of the pallet, that is, to provide an inherently rigid pallet design. In addition, it is another object in accordance with the present invention to provide an improved design for the components used in association with the vanes, such as a vane upper frame or frame. In carrying out these and other objects and objectives according to the present invention, a pallet assembly or assembly is provided which includes a cover or upper platform formed of plastic having a first opposing surface having a plurality of first flange portions. that project down from it. The upper platform portion of the pallet assembly or assembly has a substantially flat upper surface on which a plurality of objects can be spliced. The pallet assembly also includes a lower pallet portion or cover which is also formed of plastic and has a second opposing surface with a plurality of second flange portions projecting therefrom in an upward direction. In this assembly or assembly, the pluralities of second flange portions correspond to and securely engage with the plurality of first flange portions to define a plurality of columns between the upper and lower platform portions, the upper and lower platform portions. and the columns have a cross section of tubular beam to provide strength to the pallet assembly or assembly. The overall design of tubular beam vane according to the present invention also has desirable improved properties, such as increased stiffness versus weight, with respect to other standard beam section designs that have equivalent surface areas, sizes and weights, such as a T-rib beam or an inverted ü (multi-rib) design and has properties equivalent to those of the I-beam section. In a preferred assembly or assembly, the upper platform portion includes a top element and a top mid-element having corresponding mating flange surfaces that are securely coupled together. In this preferred assembly, the upper middle member has a first surface opposite the corresponding mating flange surfaces. In yet another preferred embodiment, the upper platform portion includes a lower element and a lower middle member each having corresponding mating flange surfaces which are securely coupled together. In this preferred assembly, the lower middle member has the second surface opposite its corresponding mating edge surfaces. More particularly, the first element or top element includes a substantially planar top surface with prominent ribs in a downward direction. The second upper middle member or element has a substantially planar lower surface with ribs extending in an upward direction and partial support columns extending from this surface. The ribs on these parts are aligned in such a way that they can be welded together by plasticizing their coupling surfaces, preferably by a hot plate welding operation to form a tubular beam upper platform. The third lower middle member or element has a substantially planar upper surface with ribs extending downward and partial columns extending upward. The fourth element or lower element has a substantially flat lower surface with ribs extending upwards. Again, the ribs on both sides are aligned in such a way that they can be welded together in a second hot plate welding operation to form a lower tubular beam platform. Finally, the upper platform of the tubular beam and the lower tubular beam platform are welded together on the columns that are also aligned, resulting in a pallet where each section is a tubular beam. In the preferred embodiment, each tubular section has a perforated top and bottom to allow for cleaning and drainage. These perforations can be easily removed to create true tubular sections. In a second embodiment according to the present invention, there is provided a plastic pallet assembly or assembly that includes a first pallet portion that is formed of plastic and has a first opposing surface having a plurality of first projecting portions that project downwards thereof, which define a first coupling surface. This second embodiment also includes a second pallet portion that is also formed of plastic and has a second opposing surface having a plurality of second spacing portions projecting therefrom that define a second engagement surface. Then, the plurality of first and second coupling surfaces are heated to a plasticized state, compressed together and subsequently cooled in order to define a plurality of columns to spaced apart the first pallet portion and the second pallet portion, each column, first and second blade portions define a tubular beam cross section to provide strength to the blade assembly or assembly. This method is preferably carried out by hot plate welding. In a preferred version of this second modality, the first pallet portion includes a first external element and a first internal element having opposite surfaces that are securely joined together by heating them to a plasticized state, compressing them together and cooling them. As in the first embodiment, the first external element has a first substantially flat external surface for supporting and transporting one or more objects thereon. In addition, the second blade portion may include a second external element and a second internal element having opposing surfaces securely mounted together by the process of heating the surfaces opposite a plasticized state, compressing them together and cooling them. In a third embodiment according to the present invention, a plastic blade assembly or assembly includes a first blade portion that is formed of plastic and includes an upper element and an upper intermediate element (upper middle element). Each of these elements has a first pair of substantially flat surfaces spaced apart from each other and each additionally has a first pair of coupling surfaces which are heat welded together in order to integrally define the first vane portion. The third embodiment of the plastic pallet assembly also includes a second pallet portion that is formed of plastic and includes an upper member and a lower intermediate member (lower middle member), each having a second portion of substantially flat surfaces spaced apart from each other. and each has a second pair of mating surfaces that are heat welded together in order to integrally define the second paddle portion. The first intermediate element of the first vane portion and the second intermediate member of the second vane portion each have corresponding opposite engagement edges which are heat welded together in order to integrally define the vane assembly or assembly. A fourth embodiment of the pallet assembly or assembly according to the present invention is formed substantially of plastic. The fourth embodiment includes a first external member and a first intermediate member that are separated from one another by a first pair of opposing coupling surfaces extending therebetween. The opposing coupling surfaces are integrally mounted to each other in order to define a first pallet portion. The fourth embodiment also includes a second external element and a second intermediate element that are separated from each other by a second pair of opposing mating surfaces extending therebetween. The second pair of opposing coupling surfaces are integrally mounted to each other in order to define a second pallet portion. The second intermediate element is oriented adjacent to the first intermediate element. The first intermediate element and the second intermediate element have corresponding mounting edges projecting therefrom which are integrally mounted to each other in order to define the pallet assembly or assembly. In this embodiment, the first external element includes a lower surface with edges projecting therefrom defining one of the first pair of opposing coupling surfaces and the first intermediate element having a supporting surface with corresponding edges projecting therefrom. which defines the other of the first pair of opposing coupling surfaces. The second external element includes a top surface with edges projecting therefrom, defining one of the second pair of opposite mating surfaces and the second intermediate element has a corresponding bottom surface with corresponding projecting edges thereof, which defines the other of the second pair of surfaces coupling opposite. A fifth embodiment of the portable pallet assembly or assembly according to the present invention is for storing and supporting objects on it and includes a first element having a first substantially flat upper surface on which the objects are placed and also including a first lower surface. This fifth embodiment also includes a second element having a second upper surface and a second lower surface, wherein the second upper surface is securely mounted to the first lower surface to form a plurality of tubular beam cross sections. The fifth embodiment further includes a third element having a third upper surface and a third lower surface. The third upper surface and the second lower surface have corresponding flanged surfaces which are securely mounted with each other in order to form a plurality of columns having tubular beam cross sections defined therein. This embodiment also includes a fourth element having a fourth top surface for engaging the third bottom surface and also having a fourth substantially flat bottom surface. The fourth top surface is securely mounted to the third bottom surface to form a plurality of tubular beam sections. In a preferred embodiment of this fifth embodiment, the second upper surface and the first lower surface are each mounted securely to each other by introducing heat therebetween, plasticizing each surface, compressing the surfaces together and allowing them to cool. In another preferred embodiment, the fourth upper surface and the third lower surface are mounted securely to each other by introducing heat therebetween, plasticizing each surface, compressing the surfaces together and allowing them to cool. Also described in accordance with the teachings of the present invention is an upper frame (frame or frame) for a pallet. An upper frame (frame or frame) is commonly used in relation to packaging on more objects such as empty bottles. The frame, frame or upper frame is used to help stabilize the packing of objects at the upper end relative to a pallet at the lower end. In accordance with the teachings of the present invention, a method for forming a pallet and upper frame for the pallet includes providing first and second pallet portions, each having corresponding mating flange surfaces. The method also includes introducing heat to the corresponding mating flange surfaces to fuse the mating flange surfaces in order to thereby form plasticized surfaces. The plasticized surfaces can then be pressed together and then cooled to form a weld joint therebetween which defines a plurality of tubular sections by the flanged mating surfaces. In this method, the step of providing first and second pallet portions includes assembling and aligning them in a containment fitting or retention fitting. The step of introducing heat may include introducing a heated plate therebetween. Also, the method can include the steps of retracting or restoring the heated plate from between the corresponding mating flange surfaces before pressing them together and also allowing the opening of the containment or retention fitting and removing the welded plate assembly or assembly on or near of the end of the training operation. The method may further include heating the crimped coupling surfaces under pressure by contacting the heated plate with the flanged mating surfaces to fuse them. In another embodiment of the method, more specifically the present invention provides a method for reinforcing a plastic pallet having a thin upper platform portion, a plurality of support columns extending from the upper platform portion and a plurality of carrier rails. support joined to the support columns to form a thin upper platform portion, wherein each of the support rails includes a laminar portion or sheet portion with a plurality of vertical ribs extending therefrom. The method includes the step of welding a plurality of sheets or sheets of plastic to the vertical ribs between the support columns to form a plurality of substantially rectangular hollow vertical cross-sections along the length of the support rails for improved stiffness . It is contemplated that the vertical rectangular hollow areas substantially rectangular can be filled with a secondary material, such as structural foam for improved structural integrity. The present invention also provides partial reinforcement of a plastic blade by attaching laminar strips along relatively weak structural portions of the blade to form a plurality of substantially rectangular hollow vertical cross-sections along the length of the structural portions. weak for improved stiffness without loss of impact resistance.

The above objects and other objects, features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention, when taken in conjunction with the accompanying drawings in which like reference numerals correspond to similar components.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top perspective view of a pallet assembly or assembly in accordance with the present invention; Figure 2 is a bottom perspective view of the pallet assembly or assembly; Figure 3 is a top perspective view of the exploded view of the pallet assembly or assembly showing the upper deck or deck and the lower deck or deck; Figure 4 is a bottom perspective view of the pallet assembly or assembly showing the lower deck or deck and the upper deck or deck; Figure 5 is another top perspective view of the exploded view of the pallet assembly or assembly showing the upper element, the first intermediate element (upper means), the second intermediate element (lower means) and the lower element of the pallet assembly or assembly; Figure 6 is a bottom perspective view of a pallet assembly or assembly, showing the lower element, the second intermediate element, the first intermediate element and the upper element of the pallet assembly or assembly; Figure 7 is a top perspective view of a section of the fourth part of the pallet assembly or assembly according to the invention; Figure 8 is a bottom perspective view of the section of the fourth part of the pallet assembly or assembly; Figure 9 is a top perspective view of the exploded section of the fourth part of the pallet assembly or assembly, showing the upper deck or platform and the lower deck or platform; Figure 10 is a bottom perspective view of the section of the fourth part of the pallet assembly or assembly, showing the lower deck or platform and the upper deck or platform; Figure 11 is another top perspective view of the exploded section of the fourth part of the pallet assembly or assembly showing the upper element, the first intermediate element, the second intermediate element and the lower element of the pallet assembly or assembly; Figure 12 is a bottom perspective view of the section of the fourth part of the pallet assembly or assembly, showing the lower element, the second intermediate element, the first intermediate element and the upper element of the pallet assembly or assembly; Figure 13 is a sectional view of the pallet assembly or assembly, taken along line 13-13 of Figure 7; Figure 14 is a sectional side elevational view of the exploded view, as shown in Figure 7, with the upper element, upper half element, lower middle element and lower element shown separately; Figure 15 is another sectional side elevational view of the exploded view of Figure 7, showing the upper platform and the lower platform separated; Figures 16a-f illustrate the method according to the present invention for forming and assembling the pallet assembly or assembly; Figure 17 is a perspective view of an assembly or assembly of frame, frame or upper frame according to the present invention; Figure 18 is a side view of the assembly or assembly of frame, frame or upper frame in operation with the pallet assembly or assembly and having objects to be transported disposed thereon; Figure 19 is a top plan view of the assembly or assembly of frame, frame or upper frame; Figure 20 is a front elevation view of the assembly or assembly of frame, frame or upper frame; Figure 21 is a side elevational view of the assembly or assembly of frame, frame or upper frame; Fig. 22 is a sectional view along line 22-22 of Fig. 19; Figure 23 is a sectional view taken along line 23-23 of Figure 18; Figure 24 is a bottom plan view of the first frame member, frame or upper frame, the top plan view of the second frame member, frame or upper frame is substantially similar thereto; Figure 25 illustrates an exploded perspective view of the first and second frame elements, frame or upper frame according to the present invention; Figure 26 illustrates a first frame element, frame or upper frame and second frame element, frame or upper frame partially separated; Figure 27 is a cross-sectional view taken along a line parallel to the longitudinal center line of the frame, frame or upper frame, on line 27-27 of Figure 19; Figure 28a illustrates a perspective view of a second embodiment of a frame, frame or upper frame according to the present invention; Figure 28b illustrates a partially exploded perspective view of the second embodiment of the frame, frame or upper frame; Figure 28c illustrates an exploded perspective view of the second embodiment of the frame, frame or upper frame; Fig. 29 shows a perspective view of another embodiment of a plastic pallet according to the present invention; Figure 30 shows a bottom perspective view of the exploded view of the vane of Figure 29; Figure 31 shows a top perspective view of the exploded view of the vane of Figure 29; Figure 32 shows a sectional perspective view in section of a pallet according to an alternative embodiment of the invention; Fig. 33 shows a top perspective view of the exploded view of a pallet according to a second alternative embodiment of the invention; and Fig. 34 shows a lower perspective view of the exploded view of the pallet of Fig. 33.

BEST MODE FOR CARRYING OUT THE INVENTION Figure 1 of the drawings shows a top perspective view of the pallet assembly or assembly 10 according to the present invention. The pallet assembly 10 is formed of a thermoplastic material or other polymeric material and is preferably, but not necessarily, formed of injection molded components. As illustrated in Figure 1, the pallet assembly or assembly 10 includes an upper platform 12 and a lower platform 14 that are spaced apart from each other. The pallet assembly or assembly 10 also includes a plurality of columns extending between the upper platform 12 and the lower platform 14 spaced apart. The pluralities of columns include corner column portions 16, side column portions 18 and end column portions 19 shown to extend between upper platform 12 and lower platform 14. The columns are shown to have rounded outer surfaces smooth in order to prevent damage from forklifts and the like. However, any appropriate contour can be used depending on the application. In addition to separating the upper platform 12 and the lower platform 14, the column portions 16, 18, 19 and 32 serve to support and distribute the load of the objects (for example, the bottles shown in Figure 18) placed on top of the upper platform 12 and more particularly objects designed to be supported on an upper surface 26 of the upper platform 12. In one embodiment, the upper surface 26 is preferably non-slip in order to prevent objects from slipping during transport. Again, however, any suitable surface texture or geometry can be used depending on the application without deviating from the scope of the invention. As discussed further herein, Figure 1 illustrates that the upper platform 12 and the lower platform 14 are joined together in a partition line or dividing line 20. In a preferred embodiment, the upper platform 12 and the upper platform 14 also they have a plurality of openings 22 and 24 respectively formed therethrough in order to decrease the overall weight of the pallet assembly or assembly 10, also as providing a method for draining water and other liquids / debris from the assembly or assembly 10 of pallet, in such a way that the liquids / waste do not accumulate on it. Thus, such openings or holes are particularly useful when the blade is washed. The openings or holes 22, 24 can have any appropriate shape, dimension and density and available in a variety of combinations that range from densely perforated to non-perforated depending on the desired application. Of course, the upper platform 12 and the lower platform 14 can have continuous surfaces without openings 22 and 24. As mentioned previously, the upper platform 12 includes a substantially flat upper surface 26 (first surface) on which objects and goods can be placed. be placed for transport and storage. The pallet assembly or assembly 10 also includes a plurality of openings or holes 25 for receiving the forks of a forklift therethrough (best shown in Figure 13). Figure 2 of the drawings illustrates a bottom perspective view of a pallet assembly or assembly 10. As shown therein, the lower platform 14 includes a substantially flat lower surface 28 for secure positioning on the ground or other supporting surface or also for stable orientation on a similarly designed pallet for stacking purposes. Note that the lower platform 14 also has four relatively large openings 30 located therein to accommodate pallet receptacles (sockets or sockets). Although shown substantially rectangular in shape, the openings 30 may have any suitable shape and dimension limited only by the desired application. In addition to the corner column portions 16, the side column portions 18 and the end column portions 19, a central column portion 32 is provided in the central area of the pallet assembly or assembly between the upper platform 12 and the platform. lower 14 and as its counterparts also serves to support and distribute the loads placed on the upper platform 12. Figure 3 is a half-exploded view of the pallet assembly or assembly 10 shown on the platform 12 and lower platform 14 spaced apart if on the dividing line 20. The dividing line 20 is a plane defined by the surfaces 34 and 36 of the upper and lower coupling column portion, respectively. It is the coupling column portion 34 and 36 and more particularly the coupling column surfaces 35 and 37, which are plasticized and joined together in order to assemble the pallet assembly or assembly 10 according to the present invention, as discussed further herein. As can also be seen by reference to Figure 3, the column portions 16, 18, 19 and 32 are each designed in such a way that they have a closed section or tubular section to obtain the objects and objectives summarized herein. Figure 4 illustrates a bottom perspective view in half-exploded view of the pallet assembly or assembly 10 showing the lower platform 14 and the upper platform 12 spaced apart in the divider line 20 and again shown from a different angle the portions 34 and 36 of coupling column. Figure 5 is still another top perspective view of the exploded view of the pallet assembly or assembly 10. More specifically, Figure 5 illustrates a fully exploded top perspective view of the pallet assembly or assembly 10, wherein the upper platform 12 and the lower platform 14 are each shown as separate in the four main components of the pallet assembly 10. As shown therein, the upper platform 12 has an upper element 38 (also referred to as a first element or first external element) and an upper middle element 40 (also referred to as the first intermediate element (or upper element) or first internal element) . In addition, the lower platform 14 has a lower element 42 (also referred to as a second element or second external element) and a lower middle element 44 (also referred to as a second intermediate element (lower element) 44 or second internal element). Again, as described more fully hereinafter, it is contemplated that the upper element 38 and the upper middle member 40 are coupled together to form the upper platform 12 by plasticizing the coupling surfaces via the same or similar processes used to join the upper platform 12 to the lower platform 14. Similarly, it is contemplated that the lower element 42 and the lower middle member 44 are also joined together to form the lower platform 14 via a similar process. As further illustrated in Figure 5, the upper element 38 includes the upper surface 26 on which the objects are placed to be transported or stored. Hence, it is the surface of the upper element 38 which is opposite the upper surface 26 referred to as the lower surface 46 of the upper element (best shown in the bottom perspective view of the exploded view of Figure 6) - which is attached to a flat upper surface 48 of the upper middle element 40 via the plasticizing process described for the purpose of forming the upper platform 12. As discussed previously, the lower element 42 includes the lower surface 28 for resting on floors and other supporting surfaces . The surface of the lower element 42 which is opposite the lower surface 28 - referred to as upper 50 of the lower element - is attached to a corresponding flat lower surface 51 of the lower middle element 44. Figure 6 is a bottom perspective view through complete breakdown of a pallet assembly or assembly 10 illustrating its four components as discussed previously in association with Figure 5. These features are all shown in Figure 14. Referring now to Figures 7, 12 and 13, a section 55 of the fourth part of the pallet assembly 10 illustrates in particular the tubular beam form of cross-section described herein according to the present invention. As illustrated in Figures 7, 12 and 13, a representative tubular beam section is shown for the upper platform 12, the tubular beam section defined by the upper surface 26, the flat surface 41 of the upper middle element and the pairs of coupling flange 62-72 and 63-73 which are each held together. Another representative tubular section is shown defined by the surfaces 26 and 41 and the pairs of coupling flanges 63-73 and 64-74 that are held together. Figure 13 illustrates the lower platform 14 having a representative tubular beam section which is defined by the lower surface 28, the lower average surface 45 and the coupling flange pairs 82-92 and 83-93 which are also clamped together and another section of representative tubular beam further defined by the surfaces 28 and 45 and the coupling flange pairs that are held together, these are the pairs 83-93 and 84-94. According to the invention, the preferred fastening means are by hot plate welding. However, any suitable fastener can of course be used depending on the application, in which infra-red radiation, epoxy, etc. are included without limitation. Also note that the tubular beam sections are included with respect to the column portions of the pallet assembly or assembly 10, which include the representative central column portion 32, the lateral column portion 18 and the end column portion 19. For example, the cross section through the side column portion 18, as shown in Figure 7, illustrates the presence of a tubular beam section, shown as four wall portions 18a, 18b, 18c and 18d that define a rectangular opening 27 through them. Also, with further reference to Figure 3, note that sections of tubular beam are described through the column portions, for example defined by the wall elements 2, 3, 4 and 5 of the column 20. Under equivalent applied loads, the tubular beam design described herein has improved bending and strength properties with respect to a ribbed pallet design. conventional having a ribbed support structure (such as T-rib designs or inverted U-rib designs). For example, to compensate for the lower stiffness, the T-rib will require approximately 17% increase in height compared to the tubular beam section. With particular reference to the exploded perspective views of section 55 of a quarter of the pallet shown in Figures 11 and 12, note that the coupling flanges extend through the upper platform 12 and the bottom platform 14, both longitudinal (for example ridges 62, 72, 82, 92) and transversally (for example, flanges 162, 172, 182, 192) in a perpendicular orientation and configuration, in order to define, when they are welded together, the plurality of tubular sections described heretofore. As shown in the exploded views of Figures 5, 6, 11 and 12, such tubular sections extend in a continuous manner through the upper platform 12 and the lower platform 14. More particularly with reference to Figures 11- 12, note that the tubular sections of the upper platform 12 are relatively smaller than the sections of tubular beam in the central and external areas (for example, the section of tubular beam defined by the coupling areas 21 and 21 '), in so much that they are relatively larger in the central portion of each of the sections of a room, such as the quarter section 55 (for example the section of tubular beam defined by the areas 23 and 23 A- With reference again to the Figures 11-12, it will be noted that this physical arrangement of the tubular beam section is similar for the lower platform 14, where it will be noted that the sections of tubular beam are relatively smaller and more concentrated m closer together between the openings or holes 30, in order to provide greater resistance to these areas, as will be noted by the section of tubular beam formed from the welded coupling areas 43 and 43 A On the other hand, sections of tubular beam larger of the lower platform 14 are provided towards the outer edges, such as the section formed by the welded coupling areas 33 and 33 A The tubular beam design for the upper platform 12, lower platform 14 and the column portions described in FIG. the present also obtain similar properties to a solid pallet design, but of course, by definition the tubular beam uses less material and is therefore less expensive and lighter than its solid counterpart. Further, a conventional ribbed vane design does not commonly obtain the bending or stiffness requirements of the tubular beam design in accordance with the present invention and also require a reinforced or design resin and need to be relatively higher to obtain relatively high stiffness. The conventional design also fails to comply with the desirable properties of the design according to the present invention, given weights of parts, loads and equivalent flexural modules implemented in design comparisons. With reference to Figure 8 of the drawings, there is shown in a lower perspective view of the fourth part section 55 shown in Figure 7. Figure 8 is similar to the full bottom perspective view of the vane of the Figure 2, but as mentioned is a section 55 of a quarter of the whole pallet assembly or assembly 10. Figure 9 shows a top perspective view of the section 55 of a quarter of the exploded figure 7 in the upper platform 12 and the lower platform 14. This view of the section of the fourth part is similar to the perspective view corresponding lower part of the complete pallet illustrated and previously described in association with figure 3., Figure 10 is an exploded view of a bottom perspective view of the fourth part section 55 shown in Figure 8 in exploded view in the lower platform 14 and the upper platform 12. This view is similar to the corresponding perspective view of the bottom of the complete palette of figure 4. Figure 11 is still another fully exploded view of the upper perspective view of section 55 of a fourth part shown in figure 7, showing the various elements included in the set or pallet assembly 10, which are the upper element 38, the upper middle member 40, the lower element 42 and the lower middle member 44. This view is similar to the exploded perspective view of the entire pallet of Figure 5. Similarly, Figure 12 is another fully exploded view of the lower perspective view of the fourth part section 55 of Figure 8, showing the various components included in the assembly or assembly. 10 of palette. Similar to the perspective view of the exploded view of the full vane of Figure 6. Figure 13 is a cross-sectional view of the section 55 of a quarter of the pallet assembly or assembly 10 shown in Figures 7-12. More particularly, Figure 13 is an elevation view of the section 55 of a quarter of the pallet, taken along the center line 13-13 of Figure 7. While the various elements 38, 40, 42 and 44 in a preferred embodiment are formed of a similar material, for ease of reference, it is illustrated that these elements have different shading in order to easily demarcate between the walls of the various elements as shown in this cross section. As in Figure 7, the tubular or closed beam cross section of the column portions is evident from Figure 13, represented by the side column portion 18. Particularly, Figures 13-15 illustrate the coupling portions of the pallet assembly or assembly 10 which are plasticized and joined in accordance with the present invention and mounted particularly via the hotplate welding process as discussed further herein. Note that in addition to the dividing line 20 between the upper platform 12 and the lower platform 14, there are two additional dividing lines shown, those are an upper divider line 52 defined by a plane between the upper element 38 and the upper middle element 40 and a bottom or bottom dividing line 54 defined by a plane between the lower element 42 and the lower middle element 44. The dividing lines define the respective welding planes according to the present invention. According to the present invention, each of the adjacent and attached elements of the pallet assembly or assembly 10 are preferably joined together in the flat portions or surfaces defining the corresponding divider lines 20, 52 and 54. With reference to the figure 14, it will be noted that the dividing line 20 is defined by coupling flat surfaces 35 and 37; the upper divider line 52 is defined by coupling flat surfaces 69 and 79 and the lower divider line 54 is defined by the mating flat surfaces 50 and 51. As best illustrated in the sectional view of Fig. 15 showing the pallet upper 12 and the lower platform 14 spaced apart, it is shown that the corresponding coupling ribs 100-105 of the upper platform 12 and ribs 110-115 of the lower platform 14 are plasticized and welded together, preferably by the welding process with hot plate. Similarly, as shown in the full perspective view of Figure 14, the elements forming the upper platform 12 and the lower platform 14 are similarly welded together in their corresponding coupling ribs. Accordingly, with reference again to FIG. 14, the ribs 60-67 of the upper element 38 and the ribs 70-77 of the upper middle element 40 are melted or plasticized, preferably during the hot plate welding process and welded to its corresponding coupling ribs. Accordingly, the ridges or ribs extending downwardly from the upper element 38 (flanges 60, 61, 62, 63, 64, 65, 66 and 67) are heated to a molten state and respectively joined with the coupling flanges 70. , 71, 72, 73, 74, 75, 76 and 77 respectively, which extend upwards from the upper middle element 40. Similarly, the components forming the lower platform 14 are joined in the same manner, so that the integrally molded flanges 80, 81, 82, 83, 84, 85, 86, 87 (80-87) extending upwardly from the lower element 42 are heated to a plasticized state and pressed together with respective integrally molded flanges (90, 91,92,93, 94, 95, 96, 97 (90-97) respectively, which extend downwards from the lower middle element 44. After each of the upper platform 12 and the lower platform 14 have been joined or welded, figure 15 shows that the upper platform 14 is then welded to the lower platform 12 in a similar manner, wherein the integrally molded ribs or ribs 100, 101, 102, 103, 104, 105 and their respective integrally molded opposing coupling flanges 110, 111, 112, 113 114 and 115 are heated to a molten state and then pressed together via the hotplate welding process in order to form the pallet assembly 10. Note that the welds according to the teachings of the process must be cooled before the pallet assembly or assembly 10 can reach its optimum physical properties, in which resistance and load bearing characteristics are included. Attention is now focused on the assembly method of the pallet assembly or assembly 10 according to the present invention. The preferred manufacturing assembly process is by the hot plate welding process which is best illustrated in Figure 16 of the drawings. However, as indicated above, any suitable fastening means may be used, such as for example infrared radiation, epoxy, etc. The hot plate welding process can be characterized either as hot plate welding or non-contact hot plate welding. This process should provide welding strength properties and produce seals between the coupling components (welded) as strong as those of the original polymer. According to the present invention, the welding surfaces, such as ribs 60-67, 70-77, 80-87, 90-97, 100-105 and 110-115 are either placed in contact (in the welding process) with hot contact plate) or closely (in the non-contact variation) approach a heated plate 126 (preferably formed of steel) or similar tool in order to create a molten or plasticized region on the ribs mentioned above. Then, the plate 126 is removed and then the plasticized regions are pressed together to form the weld. More particularly, in practice, the process is put into operation on a hot plate welding machine (known in the art) in which the corresponding blade elements that are to be welded together are fastened on carriers 122 and 124. plate 126 of the welding machine, which is heated to a predetermined desirable temperature, advances between the separate coupling parts (for example the upper platform 12 and the lower platform 14), after which the welded planes of the blade elements to be soldiers are either pressed against the plate (contact version using heat by conduction) or are moved closely to it (non-contact version using radiant heat). The choice of which method to use is dependent on many factors that include the properties of the materials to be welded; Required cycle times; size and design of the component; accuracy and repeatability of the welding machine and use of the welded component. In the process of welding with hot contact plate, the heat is conducted by physical contact of the parts to be welded with the heated plate 126. In addition, the surface of each coupling vane element is plasticized or melted until it is completes the contact (referred to in the art as "pairing"). At this point, further movement of the plate 126 is stopped and heating is continued, in order to create a plasticized zone deeper (at a predetermined depth) and relatively more molten in which the material is displaced. In the non-contact process, radiant heat is applied to the parts to be welded, which is generated by keeping the parts to be welded very close to the heated plate (target plates) and allowing them to warm up over time. Either for one version or another, after the heating is complete and the melting surface has reached a predetermined melt depth, the parts are removed from the heated plate 126. Then the plate 126 is removed, after which the Attached vane elements (e.g., upper platform and lower platform 14) are forged together and retained until the polymer of the plasticized vane element surfaces is cooled. Mechanical or microprocessor controlled seals can be used to control the amount of material displacement of the palette polymer from the welded zone particularly during the heating phase. Of course, as stated previously, the process described herein is applicable for joining the upper platform elements 38 and 40 and the lower platform elements 42 and 44. If the polymers between the attached pallet elements are compatible, the process Welding with hot plate is suitable for welding dissimilar thermoplastics with the use of two plates that compensate the different melting or softening points of the polymer. Hot plate welding is preferably used with standard unfilled or non-reinforced polymers and is preferably used in this manner in accordance with the pallet assembly or assembly 10 of the present invention. However, hotplate welding can be used to assemble the pallet assembly or assembly 10 with filled or reinforced polymers, provided that the filler or reinforcing material allows the polymer to inter-diffuse after forging. The welding times for forming the pallet assembly 10 may vary with the volume of the polymer to be melted and the thermal conductivity of the respective blade element. Thus, the welding times for the pallet assembly or assembly 10 may fall in the range of 5 to 60 seconds, although the mass of the pallet elements to be plastified and the corresponding cooling speeds will determine the cycle times. The size of the pallet assembly or assembly 10 which can be welded by hot plate according to the present invention is limited only by the practical size of the retaining fittings 122 and 124 and the plate 126 of the welding machine and also of the mechanics of the removal of the set or welded sub-assembly of the welded zone and movement of the components of the pallet assembly or assembly 10 to forge them together. Each of the contact and non-contact methods has its advantages, which include: In the non-contact method, no coating on the plate 126 is required for material release, no residue accumulates on the plate 126, there is no loss of weld edge material against the heated plate 126 and the finished parts have consistent welding characteristics. While the advantages of contact heating are: faster cycle time, a lower temperature required for plate 126, the method is more tolerant to larger design components, such as the vane element described herein and also more tolerant to less dimensionally consistent components. As shown in Figure 16a, the hotplate welder has attachment fittings 122 and 124 of parts attached thereto. The parts to be welded, for example and without limitation, the upper platform 12 and the lower platform 14 are secured to their respective retention fitting 122 and 124. With reference to Figure 16b, the plate 126 extends to and is inserted between palette elements 12 and 14 that are going to be soldiers. Each of the retention fittings 122 and 124 move towards each other and towards the plate 126. If a contact weld is desired, as shown in Figure 16c, the retention fittings 122 and 124 approach the plate. 126 to the surfaces of the platforms 12 and 14 that are to be welded (surfaces 35 and 37). If a non-contact welding of the pallet assembly or assembly 10 is desired, then Figure 16c is ignored and the surfaces 35 and 37 of the platforms 12 and 14 do not contact the plate 126. As shown in Figure 16d , after a predetermined period of time, the retaining fittings 122 and 124 begin to separate and the plate 126 is removed from between the fittings 122 and 124. With reference to Fig. 16e, the fittings 122 and 124 are started to move the one towards the other to a welded position, in such a way that the mating surfaces of the upper platform 12 and the lower platform 14 are in contact. The upper platform 12 and the lower platform 14 are held in this final welding position for a predetermined period of time until the welded material is stable and allowed to cool. Finally, with reference to Figure 16f, the fittings 122 and 124 are separated to their loading position of parts and the welded paddle assembly 10 is retained to one of the accessories (shown in Fig. 16f as accessory 124) for unloading. Then the part is removed from the welding machine. The welding of the pallet assembly 10 as described herein provides a high strength weld suitable for the parts operating under pressure. The joined divider lines 20, 52 and 54 are relatively inconspicuous. In addition no other joining method is required, such as adhesives, solvents, mechanical fasteners such as nails or staples. Also, complex shapes such as the upper platform 12 and lower platform 14 can be welded since there is no relative movement required in the welding process. Another assembly process known as infrared radiation can also be used as a non-contact alternative to hot plate welding for use in the formation and assembly of the pallet assembly or assembly 10 according to the present invention. In such a process, infrared radiation is often supplied by high intensity quartz lamps that produce radiation wavelengths of about one meter. As with hot plate welding, when this radiation is applied to flat surfaces 35, 37, 46, 48, 50, 51 of assembly 10, plasticization is presented. In one application, the source of radiation, such as hot lamps, are removed after the fusion has occurred and the parts are forged together just as with the plate in the hot plate weld. Infrared welding tends to melt the area relatively quickly. Hot plate welding uses conduction to create the necessary plastic zone. Of course, as with any other process, the penetration depth of the plasticization depends on many factors and varies greatly with only minor changes in the polymer formulation. Attention is now focused on the load-bearing properties of the pallet 10. In a stacking scenario, the pallet 10 is supported from below on two opposite edges and loaded from above on the upper surface 26 of the upper platform 12. Pallet 10 must support this load with a minimum of bending. According to standard beam formulations known in the art, it is recognized that bending increases as the load or distance of extension increases and decreases as the modulus (E) of the material or moment of inertia (I) of the section increases. Since loading and extension are defined for a given application, the variables used to minimize bending are the material and the design of the section.

In general, as the value of E increases for a given material, the impact resistance decreases. There are design materials that can solve these problems but are too expensive for extensive use. The most common method is to use a utility resin such as polyethylene or polypropylene and add a filler to reinforce the resin. However, the fillers add weight and reduce the impact resistance for a given material, as well as impact the recycling capacity in some cases and add to the cost. Preferably, a pallet will use a resin for utility due to cost, weight and impact resistance. Thus, the optimization of the pallet design is the preferred method to obtain improved pallet performance. As indicated previously, for a given section geometry, the highest I value is for a solid section. For example, in the pallet assembly 10, the stiffer upper platform design 12 is one that is solid plastic, but is not practical due to weight and cost. Most designs attempt to overcome this by using ribbed sections instead of solid sections to minimize the loss of I and reduce the weight to an acceptable level. Another method is to use foaming agents together with the ribs to minimize the weight of the ribs and improve the value of I. Both methods have a limit to their effectiveness. That is to say, ribs are not the ideal geometry to maximize the value of I and while foaming improves this slightly, it also reduces the impact resistance of the material. In general, for a given section, the material closest to the axis or neutral center has the least effect on I and the furthest material has the greatest effect. In other words, a hollow or beam section in I is stiffer than a rectangular section of equal height and area. Thus, the pallet 10 according to the present invention defines hollow or tubular sections throughout the pallet and in a continuous manner. Conventional injection molding techniques make this virtually impossible. Accordingly, the use of a three (3) step fastening operation (preferably welding) results in a tubular beam blade 10 formed from four individual component elements 38, 40, 42, 44 which are preferably molded by injection. In summary, the first element or upper element 38 preferably includes a substantially flat upper surface with prominent ribs in a downward direction. The second upper middle member or element 40 has a substantially planar lower surface with ribs extending in an upward direction and partial support columns extending downwardly from this surface. The ribs on both of these parts are aligned in such a way that they can be welded together by plasticizing their coupling surfaces preferably via a hotplate welding operation to form a tubular beam upper platform. The third lower middle member or element 44 has a substantially planar upper surface with ribs extending downward and partial columns extending upwardly. The fourth element or lower element 42 has a substantially planar lower surface with ribs extending upwards. Again, the ribs on both sides are aligned in such a way that they can be welded together in a second welding operation with hot plate to form the lower platform 14 of tubular beam. Finally, the upper tubular beam platform and the lower tubular beam platform are welded together in the columns (16, 18, 19, 32) which are also aligned, resulting in a pallet where each section is a tubular beam. Note that with the order of the plasticizing process is provided for illustrative purposes only and of course such steps can be carried out in any feasible order. Of course, it is also contemplated in accordance with the present invention that tubular beam sections «& - ...-».,. they can be formed by a flat surface which is the ribbed area defining an area of U (for example in figure 14, between the upper element 38 and the upper middle element 40, the ribs 63, 64 and the surface 9 define an area in U or a section of partial tubular beam) while the flat coupling surface 48, instead of including ribs, form a flat surface, thereby creating a fourth wall that closes the U-shaped area and defines a tubular section. Again, of course, this will be applied to all surfaces to be welded by hot plate according to the present invention. In the preferred embodiment, each tubular section has a plurality of perforations or openings 22, 24 in the upper and lower platforms to allow for cleaning and drainage. These perforations can be easily removed to create true tubular sections. More particularly, the openings 22 in the upper element 38, the openings 57 in the upper middle element 40, the openings 24 in the lower element 42 and the openings 59 in the lower middle element 44 are tapered in such a way that they become increasingly larger from the upper surface 26 to the lower surface 28 or from the washing side to the unwashed side, in order to provide easy drainage of the water through the vane 10 (see Figures 5-6).

While there are other methods for forming the plastic parts, these methods are not capable of forming the present design. For example, blow molding is limited to hollow sections and can not create transverse ribs within the hollow sections to form the smaller tubular sections defined by the ribs of the present invention that help to obtain the desired stiffness. The extrusion is also limited in that the hollow sections and inner ribs must be oriented in the same direction for a given component. The extrusions also have open ends that must be sealed in a secondary operation to create a "clean" pallet and therefore are labor intensive and expensive to produce. It will be noted that the design according to the present invention preferably includes complete and continuous tubular beam sections throughout the entire pallet 10, that is, each section is completely tubular in: the upper platform 12, the lower platform 14 and columns 16, 18, 19, 32. The observations and revelations made in the present with respect to the module (E) of the material, moment of inertia (I), section geometry, beam formulas and rigidity are applied in general to all the modalities and characteristics described in this application.

With now focusing on Figures 17-27, a top frame 210 for a pallet is also described in accordance with the teachings of the present invention. An upper frame is commonly used in relation to the mass packaging of objects, such as empty bottles (see Figure 18). The upper frame is used to help stabilize the upper part of a package or shipment of objects in conjunction with a pallet at the bottom of the package. The upper frame 210 is preferably and generally symmetrical around each centerline and is formed of a thermoplastic material and other polymeric material and is preferably but not necessarily formed of injection molded components. With reference to Figures 17-27, there is shown an upper frame assembly (frame or frame) 210 according to the present invention. The tubular beam design according to what is described herein for the pallet 10 is also applicable to the assembly or assembly of the upper frame 210. Figure 17 illustrates a perspective view of the upper frame assembly 210. The frame assembly 210 (frame or frame) includes a (first) top element 212 and a (second) bottom element 214 (see exploded perspective views of FIGS. 25 and 26). Figure 18 shows the assembly or assembly 10 of upper frame in operation. As illustrated in them, a pallet such as the pallet 10 according to the present invention, has loaded thereon a plurality of layers of objects for transport and storage. Such objects are shown in Figure 18 as a plurality of empty bottles 216, but of course they can be any of several objects that can be transported by and stored on the pallet and to which the teachings in accordance with the present invention would be applied. A first bottle layer 216 is loaded onto the paddle 210. Normally, a flat element 218 is positioned on the upper surface of the bottles 216. The flat element 218 can be referred to as a slip sheet in the art and is commonly formed of cardboard or fiberboard. As illustrated, another layer of bottles 216 can be disposed above flat element 218 and then another flat element 218 is positioned on top of that layer of bottles 216. This method is repeated by as many layers as practical and desirable, for example, eight layers of bottles shown in figure 18. After the last flat element is positioned, the upper frame 210 is positioned on top of the flat element, in such a way that the product is walled. The pallet 10 and the upper frame 210, with the objects disposed therebetween, are tied together by strips 220. As shown in figures 17, 18, 19 and 26, the upper frame 210 also preferably includes a series of recesses. 221 around its perimeter in which the strips 220 are positioned in such a way that they do not move or move easily during packaging. Subsequently, the resulting package (as shown in Figure 18) is normally covered and protected, such as by the application of a shrinkable plastic wrap. Figure 19 illustrates a top plan view of the upper frame 210. As shown therein, the upper frame 210 includes four openings 244 defined by the outer rail 246 and transverse rails 248, 249. The openings 244 help to lower the weight of the upper frame 210 while the described tubular beam sections provide the desired strength and stiffness to the upper frame 210, similar to the properties described with respect to the blade 10. Figure 20 illustrates a front side elevation view of the upper frame 20 , showing in particular side 236. Figure 21 shows a side elevation view of upper frame 210, particularly illustrates side 221. Figure 22 illustrates a cross-sectional view of sectional line 22-22 of figure 19. Figure 23 illustrates another cross-sectional view of sectional line 23-23 of Figure 19. Figure 24 illustrates a bottom plan view of the first upper frame element 212. Upper frame 210 includes a first pair of opposite edges 220, 222 and a second pair of opposite edges 224, 226. Edge 220 of the upper frame is defined by first and second edges of upper frame member 228 and 230 respectively, the upper frame edge 222 and edges 232 and 234 of the element respectively; the edge 224 of the upper frame by elements 236 and 238 of the element respectively and the edge 226 of the upper frame by the edges 240 and 242 of the element respectively. According to the present invention, the first element 212 of the upper frame and the second element 214 of the upper frame are fastened together in a method substantially similar to that described herein in association with the fastening or welding of the blade 10, the upper platform 12 of the pallet and lower platform 14 of the pallet. With reference to Figures 25, 26 and 27, for example, the first upper frame element 212 includes a substantially planar upper surface 213 and a plurality of ribs, for example ribs 250, 251, 252, 253, 254, 255, 256 , 257, 258 and 259 (250-259) outstanding in a downward direction. The second upper frame member 214 has a substantially planar lower surface 217 with a plurality of ribs 260, 261, 262, 263, 264, 265, 266, 267, 268, and 269 that extend in an upward direction and with respect thereto. which engage with those ribs 250-259 respectively of the first upper frame element 212. Figure 27 illustrates a cross-section of the upper frame 210 taken along the line 27-27 of Figure 19. Figure 27 illustrates that the joint or welding of each of the respective pairs of ribs 250-259 and 260 -269 defines tubular beam section walls 270, 271, 272, 273, 274, 275, 276, 277, 278, 279 of the upper frame 210. Likewise, for example, the ribs 280, 281, 282, 283, 284, 285, 286, 287, 288, 289 of the first upper frame member correspond to and engage the ribs 290, 291, 292, 293, 294, 295, 296, 297, 298, 299 respectively of the second upper frame member. The corresponding ribs on both elements 212, 214 are aligned in such a way that they are preferably welded together when plasticizing their coupling surfaces preferably via a hot-plate welding operation to form the upper beam frame assembly 210. resulting in an upper frame where each section is of tubular beam. Note that the order of the plasticizing process is provided for illustrative purposes only and of course, such steps can be carried out in any feasible order. Also, as with the pallet 10, the plasticizing process for the upper frame can also be carried out by infrared radiation or other process designed to provide the desired properties of the upper frame 210. The first upper frame element 212 and the second element 214 of upper frame have corresponding flat surfaces 211, 215 which when coupled together and fastened define the dividing line 219. Thus the flat surfaces 211 and 215 include the corresponding upper or lower edges of the ribs 250-259, 260-269 , 280-289 and 290-299. The upper frame 210 thus provides greater load stability, which allows the objects 216 to be stacked higher and with greater stability. Further, with the upper frame 210 positioned and secured above the stack, it is contemplated that another blade, such as the blade 210, may be stacked on top of the upper frame 210. The tubular beam sections extending through the upper frame 210 they also provide improved stiffness and resistance to the part and minimize any arcing or bending of the part and also minimize or prevent any deformation resulting from the application of strips 220 to an upper wooden frame. The upper frame 210 also includes a recess 223 for receiving a rim (not shown) therein to provide skid or slip resistance when stacked on top frames. Figure 28a illustrates a perspective view of a second embodiment of an upper frame 210 'in accordance with the present invention. Similar reference numbers are assigned to characteristics similar to those described in the first upper frame mode, with a premium designation ('). As further illustrated in the exploded views of Figs. 28b and 28c, the upper frame 210 'includes an outer rail 246' and has a single opening 244 '. The upper frame 210 'also includes recesses 221' for receiving strips therein. Thus, with reference to the first and second top frame embodiments 210 and 210 ', it is contemplated that the top frame according to the present invention may have several designs without deviating from the teachings in accordance with the present invention. Thus, the upper frame 210 'includes sections of tubular beam around and between the components of the first upper frame member 212' and the second upper frame member 214 ', which define the rail 246' as illustrated in Figures 28b and 28c . In the same manner as described with respect to the upper upper frame 210, the upper frame 210 'also includes flat coupling surfaces 211' and 215 'which when fastened according to the teachings of the present invention define sections of tubular beam in them, also as the dividing line 219 'between the first upper frame element 212' and the second upper frame element 214 '. Accordingly, this alternative design of the upper frame assembly or assembly 210 'has the stiffness and desired properties as described in relation to the upper vane 10 and upper frame 210. Referring now to Figs. 29-34, an alternative tubular beam design according to the present invention and in association with Figs. 29-34 is also described. While the tubular beam design according to the present invention and shown in Figs. 29-34 provides many advantages hitherto found in the art, the mode shown and described in association with Figs. 29-34 in relation to the previous embodiments, may fully obtain the properties and characteristics of the above pallet 10, because many areas which may limit bending may have a tubular section in this alternative tubular beam section design. In a stowage scenario, the plastic pallet 310 (which is configured to receive a pallet receptacle (socket) from either side), shown in FIG. 29, is supported from below on two opposite edges 312, 314 and loaded on the 316 portion of upper platform. The pallet must support this load with a minimum of bending. The upper platform portion 316 is supported by a plurality of support columns 318 that extend from the upper platform portion 316 and attached to the support rails 320, which form the lower platform 319. The support rails 320 are in general relatively weak structural portions of the pallet because they are thin in vertical cross section and are supported only at opposite ends by the columns 318. Thus, the support rails 320 tend to flex when the pallet is loaded. As mentioned above, the bending decreases as the moment of inertia (I) of the section increases. For a palette, the easiest method to increase stiffness is to increase the height. However, in practice there is a maximum allowable height for the pallets and the existing pallets are designed er. general to this maximum value. Thus, the only alternative is to maximize the moment of inertia for the pallet and particularly for each pallet component, i.e. upper platform 316, the lower platform and lanes of: support 320.

Therefore, the purpose of the design is to create hollow or tubular sections wherever possible. Conventional injection molding techniques make this almost impossible to create, but by using a secondary operation it is possible to form an upper platform 316 and lower platform 319 tubular. A pallet according to the present invention includes the upper platform portion 316 which is conventionally injection molded and consists of a flat upper surface 322 with a series of prominent ribs 324 of the upper surface 322, as shown in Figure 30. The upper platform portion 316 includes a plurality of cavities 326 for receiving the support columns 318. A plurality of plastic sheet strips 328 are sonically welded to the ribs 324 to form a plurality of substantially rectangular hollow tubular sections between the cavities 326 within. of the upper platform 316 (as described below with reference to figure 32). Alternatively, other joining methods such as vibrating welding, hot plate welding, adhesive, etc., can be used for joining the plastic sheet strips 328. The lower platform 319 is similarly constructed, but has the supporting columns 318. molded integrally with it. The ribs 330 protrude downwardly from the laminar portions 332 of the support rails 320 and a plurality of plastic lamellas 334 are welded to the ends of the ribs 330 to form a plurality of tubular cross sections along the length of the ribs. the rails 320 between the columns 318. The upper and lower platforms 316, 319 may be permanently joined by welding or may be inserted together as is commonly known in the art. The method described above is preferably used to reinforce conventional ribbed vane designs. The small plastic sheets 334 are welded to the critical bending areas of the existing pallets for reinforcement. Also, new pallets could be designed to accept the sheets for applications that require stowing and would eliminate the sheets by lighter applications of lower cost. For example, the ribs 330 may be recessed in order to receive the sheets 334 in a level position with the lower surface of the support rails 320. The method described above is particularly applicable for use in pallets such as that shown in the figure. 29, which has a top platform 316 and bottom platform 319 very thin to allow the tetradirectional entry of receptacles or pallet sockets. The described method can be used to maximize the moment of inertia of each platform element. With reference to Figure 32, an alternative embodiment of the invention is shown. Similar to the embodiment shown in Figure 29, the lower platform rails 340 include a sheet portion 342 with a plurality of vertical ribs 344 extending therefrom. The plastic sheet strips 46 are welded to the ribs 344 to form the plurality of substantially rectangular hollow vertical cross sections 348 along the length of the support rails 340. Of course, numerous ribs 344 could be added to create numerous sections rectangular cross-sections for additional structural integrity. The pallet shown in Figure 32 differs from the previous embodiment described with reference to Figures 29-31 in which a large sheet or sheet 350 is welded to the ribs 352 through the extension of the upper platform 354 for improved structural integrity of the upper platform 354. It is contemplated that good results could still be obtained by simply welding the peripheral ribs to the plastic sheet strips. It is further contemplated that plastic sheet strips do not need to be welded, but could be fixed in any other way, such as adhesive, etc. It is also contemplated that the sheet strips do not need to be plastic. With reference to Figures 33 and 34 another alternative embodiment of the invention is shown. In this embodiment, the pallet 410 includes a thin upper platform 416 attached to a thin lower platform 419 by nine support columns 418. The lower platform 419 includes a plurality of support rails 420 that extend between the columns 418. Each rail support 420 includes a sheet portion 422. Because each support rail 420 forms a relatively weak structural portion of the blade 410, a rectangular tube 427 of extruded plastic is welded against each respective sheet portion 422 to add rigidity to each support rail by forming substantially rectangular vertical cross sections along the length of each support rail 420. Similarly, the upper platform 416 includes open channels 428 adjacent the upper sheet 430 and a rectangular extruded plastic tube 431 is welded into each channel 428 against the upper sheet or sheet 430 between the columns 418 to form sections vertical cross-sections substantially rectangular along the length of each channel 428 between the columns 418 for improved stiffness. In this configuration, the rectangular tubes 427, 431 can be extruded in a non-expensive manner and add substantial structural integrity to the pallet 410 without limiting the ability of the pallet to receive pallet receptacles (sockets or plugs) from either side thereof. While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation and it will be understood that various changes can be made without deviating from the spirit and scope of the invention. It is noted that, in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (47)

1. CLAIMS Having described the invention as above, it is claimed as property, what is contained in the following claims: 1. A set or assembly of plastic pallet, characterized in that it comprises: a platform or top cover having a plurality of sections of upper tubular beam disposed therein and having a first opposite surface having a plurality of first column portions projecting down therefrom and a lower platform having a plurality of lower tubular beam sections disposed therein and having a second opposing surface having a plurality of second column portions projecting therefrom, the plurality of second column portions correspond to and securely engage with the plurality of first column portions to define a plurality of cross sections of tubular beam between the upper platform and the platform lower jaw to provide resistance to the pallet assembly or assembly.
2. 2. The plastic pallet assembly or assembly according to claim 1, characterized in that the upper platform includes an upper element and an upper middle element, each having correspondingly attached flange portions defining the plurality of beam sections. tubular upper.
3. 3. The plastic pallet assembly or assembly according to claim 1, characterized in that the lower platform includes a lower element and a lower middle element, each having corresponding fastening flange portions defining the plurality of beam sections. lower tubular.
4. A pallet assembly or assembly, characterized in that it comprises: a platform portion or top cover formed of plastic having a first opposing surface having a plurality of first flange portions projecting down therefrom and a portion of lower platform formed of plastic and having a second opposing surface having a plurality of second flange portions projecting up therefrom, the plurality of second flange portions correspond to and securely engage with the plurality of first portions of flange to define a plurality of tubular beam cross sections between the upper and lower platform portions to provide strength to the pallet assembly or assembly.
5. 5. The pallet assembly or assembly according to claim 4, characterized in that the upper platform portion includes an upper element and an upper means element having corresponding mating flange surfaces which securely engage with each other to define a plurality of upper tubular beam sections, the upper middle element has the first surface opposite its respective surface of the corresponding flanged coupling surfaces.
6. The pallet assembly or assembly according to claim 4, characterized in that the lower platform portion includes a lower element and a lower intermediate element having corresponding mating flange surfaces that are securely coupled together to define a plurality of lower tubular beam sections, the lower middle member has the second surface opposite its corresponding mating flange surfaces.
7. The pallet assembly or assembly according to claim 4, characterized in that the upper platform portion has a substantially flat upper surface on which a plurality of objects are able to rest.
8. A pallet assembly or assembly, characterized in that it comprises: a first pallet portion formed of plastic and having a first opposite surface having a plurality of first separating portions projecting down therefrom and having a first surface of coupling and a second portion of vane formed of plastic and having a second opposing surface having a plurality of second separating portions projecting therefrom having a second coupling surface, the plura of first and second coupling surfaces are heated to a plasticized state, compressed together and cooled to define a plura of columns to separate the first blade portion and the second blade portion, each column having tubular beam cross sections for Provide resistance to the assembly or assembly of pallet.
9. The pallet assembly or assembly according to claim 8, characterized in that the first pallet portion includes a first external element and a first internal element having opposite surfaces that are securely joined to each other by heating the surfaces opposite to a plasticized state, compressing them together and cooling them.
10. The pallet assembly or assembly according to claim 9, characterized in that the first external element has a first substantially flat external surface for supporting and transporting an object thereon.
11. The pallet assembly or assembly according to claim 8, characterized in that the second blade portion includes a second external element and a second internal element having opposite surfaces that are securely mounted to each other by heating the opposite surfaces. to a plasticized state, compressing them together and cooling them.
12. A pallet assembly or assembly, characterized in that it comprises: a first blade portion formed of plastic and including an upper element and an upper intermediate element, each having a first of a first pair of substantially flat surfaces spaced apart from each other and each also has one of a first pair of mating surfaces which are heat welded together to integrally define the first blade portion and a second blade portion formed of plastic and which includes a lower element and a lower intermediate element, each one has one of a second pair of substantially planar surfaces spaced apart from each other and each defines further has one of a second pair of coupling surfaces that are heat welded together to integrally define a plura of tubular beam sections in the second portion of pallet, where the first intermediate element The first pallet portion and the second intermediate element of the second pallet portion have opposite mating edges that are welded together to join the first and second pallet portions.
13. A pallet assembly or assembly formed substantially of plastic, characterized in that it comprises: a first external member and a first intermediate member spaced apart from each other by a first pair of opposing coupling surfaces extending therebetween which are integrally mounted between si to define a first vane portion having a plura of cross beam sections extending longitudinally and transversely through the first vane portion and a second external member and a second intermediate element spaced apart from each other by a second pair of vanes; opposing mating surfaces extending therebetween which are integrally mounted together to define a second vane portion having a plura of tubular beam sections extending longitudinally and transversely through the second vane portion, the second element intermediate is oriented or adjacent to the first intermediate element, wherein the first intermediate element and the second intermediate element have corresponding flat mounting edges projecting therefrom which are integrally mounted together to define the pallet assembly or assembly.
14. The pallet assembly or assembly according to claim 13, characterized in that the first external element includes a lower surface with edges projecting therefrom defining one of the first pair of opposing coupling surfaces and the first intermediate element has a top surface with corresponding edges projecting therefrom defining another of the first pair of opposite mating surfaces and wherein the second external element includes a top surface with edges projecting therefrom, which defines one of the second pair of opposed mating surfaces and the second intermediate element has a lower surface with corresponding edges projecting therefrom, defining another of the second pair of mating mating surfaces.
15. A pallet assembly or assembly for storing and transporting objects thereon, characterized in that it comprises: a first element having a first substantially flat upper surface on which the objects are placed and a first generally flat lower surface defined by a plurality of rib elements that extend downwards; a second element having a second upper surface and a second generally flat lower surface defined by a plurality of vertical rib elements corresponding to the rib elements extending downwardly from the first element and securely mounted therewith to define a plurality of tubular beam sections, the second upper surface is securely mounted to the first lower surface; a third element having a third upper surface and a third generally flat lower surface defined by a plurality of rib members extending downward, the third upper surface and the second lower surface having corresponding flat flanged surfaces mounted securely between yes to form a plurality of columns having tubular beam cross sections and a fourth element having a generally flat upper fourth surface defined by a plurality of vertical rib elements corresponding to the rib elements extending downward from the third element and securely mounted therewith to define a plurality of tubular beam cross sections and a fourth substantially flat bottom surface, the fourth top surface is securely mounted to the third bottom surface.
16. 16. The pallet assembly or assembly according to claim 15, characterized in that the second upper surface and the first lower surface are mounted securely by introducing heat therebetween, plasticizing each surface, compressing the surfaces together and allowing them to cool.
17. The pallet assembly or assembly according to claim 15, characterized in that the fourth upper surface and the third lower surface are mounted securely by introducing heat therebetween, plasticizing each surface, compressing the surfaces together and allowing them to cool.
18. 18. A method for forming a pallet, characterized in that it comprises: providing first and second pallet portions, each having a pair of flat surfaces with a plurality of tubular sections formed therebetween and extending through the first and second ones. pallet portions, the first and second pallet portions have corresponding mating flange surfaces; introducing heat to the corresponding mating flange surfaces to melt the mating flange surfaces thereby forming plastified surfaces; pressing the plasticized surfaces together and cooling the plasticized surfaces forming a welded joint therebetween defining a plurality of column elements extending between the first and second blade portions, each column element having a plurality of tubular sections formed therein same.
19. The method according to claim 18, characterized in that the provision of first and second pallet portions includes assembling and aligning them in a retention fitting.
20. The method according to claim 19, characterized in that it further comprises opening the retaining fitting and removing the welded vane assembly or assembly.
21. The method according to claim 18, characterized in that the introduction of heat to the corresponding flanged coupling surfaces includes introducing heat to a heated plate therebetween.
22. 22. The method according to claim 18, characterized in that it further comprises: removing the heated plate from between the corresponding mating flange surfaces.
23. 23. The method according to claim 18, characterized in that it comprises heating the crimped coupling surfaces under pressure by contacting the heated plate with the flanged coupling surfaces to melt them.
24. 24. A method for forming a plastic pallet assembly or assembly, characterized in that it comprises: providing a platform or upper cover portion having a plurality of tubular beam sections of the entire upper cover disposed therein and having a first opposite surface with a plurality of first column portions projecting towards down the same as defining first sections of partial tubular beam; providing a lower platform or deck portion having a plurality of tubular beam sections of the lower platform disposed therein and having a second opposing surface with a plurality of second column portions projecting therefrom that define it second partial tubular beam sections and securely join the plurality of second column portions to the corresponding plurality of first column portions to define a plurality of complete tubular beam cross sections between the upper platform and the lower platform to provide resistance to the assembly or pallet assembly.
25. 25. A set or assembly of frame (frame or frame) upper suitable for use with a pallet, where the assembly or assembly of upper frame and pallet have at least one layer of objects positioned between them, assembly or assembly frame (frame or frame) upper is characterized in that it comprises: first and second upper frame elements, the first upper frame element has a first plurality of ribs extending downward thereof, the second frame element has a second plurality of ribs extending up therefrom to engage with the first plurality of ribs, the first and second plurality of ribs clamped together to form a plurality of sections of complete tubular beam between the first top frame member and the second rib element. upper frame.
26. 26. An upper frame (frame or frame) suitable for use with a pallet having at least one layer of objects to be transported positioned between the upper frame and the pallet, the upper frame is characterized in that it comprises: a first upper frame element which it has a plurality of ribs extending downward thereof, which define a first plurality of partial tubular beam sections thereon and a second upper frame member having a corresponding plurality of vertical ribs extending therefrom which define a second plurality of partial tubular beam sections, the ribs extending downward and the corresponding vertical ribs joined together to form a plurality of complete tubular beam sections extending longitudinally and transversely between the first upper frame member and the second upper frame element.
27. 27. The upper frame of claim 26, characterized in that the ribs extending downwards and the ribs extending upwards are joined to the plasticizers and welded together.
28. 28. The upper frame of claim 26, characterized in that the plurality of complete tubular beam sections extend between opposite edges of the upper frame.
29. 29. A method for forming an upper frame for use with a vane, characterized in that it comprises: providing a pair of upper frame elements, each having a corresponding plurality of ribs defining a pair of ribbed surfaces for coupling therebetween; introducing heat to the ribbed surfaces to form plasticized coupling surfaces; pressing the plasticized coupling surfaces together and cooling the plasticized coupling surfaces forming a welded joint therebetween, which define a plurality of tubular sections extending between the pair of upper frame elements.
30. 30. The method of claim 29, characterized in that the provision of a pair of upper frame elements includes mounting and aligning them in a holding fixture.
31. 31. The method of claim 30, characterized in that it further comprises opening the retaining fitting and removing the welded pair of upper frame elements.
32. 32. The method of claim 29, characterized in that the introduction of heat to the ribbed and coupling surfaces includes introducing a heated plate therebetween.
33. 33. The method of claim 29, characterized in that it further comprises retracting the heated plate from between the corresponding ribbed and mating surfaces.
34. 34. The method of claim 29, characterized in that it further comprises heating the ribbed and coupling surfaces under pressure by contacting the heated plate with the ribbed coupling surfaces to melt them.
35. 35. A method for forming an upper frame assembly (chassis or frame), characterized in that it comprises: providing a first upper frame element having a plurality of first rib elements projecting therefrom defining a plurality of ribs. upper partial tubular beam sections having a first flat coupling surface; providing a second upper frame member having a plurality of second rib elements projecting therefrom defining a plurality of partial lower tubular beam sections having a second mating surface corresponding to the first mating and joining surface The first engagement surface with the second engagement surface is securely defined to define a plurality of complete tubular beam sections between the first upper frame member and the second upper frame member to provide strength to the upper frame assembly or assembly.
36. 36. A method for reinforcing a plastic pallet having a plurality of relatively weak structural portionseach includes a sheet portion or sheet portion with a plurality of vertical ribs extending therefrom, wherein the sheet portion or web portion and ribs cooperate to form a plurality of vertical U-shaped cross sections as Along the length of the vane and each U-shaped cross section has an open end, the method is characterized in that it comprises: fixing a plurality of flat laminar strips to the vertical ribs in the plurality of relatively weak structural portions, respectively, for Completely closing the open ends of the U-shaped cross sections to form a plurality of rectangular hollow vertical cross-sections along the length of the relatively weak structural portions for improved stiffness.
37. 37. The method of claim 36, characterized in that the step of securing a plurality of laminar strips comprises welding a plurality of plastic laminar strips.
38. 38. The method of claim 37, characterized in that the welding step comprises sonic welding.
39. 39. The method of claim 36, characterized in that the plastic blade comprises an inventory resin material having a flexural modulus of less than 14.060 Kg / square centimeter (200,000 pounds / square inch).
40. 40. A method for reinforcing a plastic pallet having a top platform portion, a plurality of support columns extending from the upper platform portion and a plurality of support rails attached to the support columns, wherein Support rails include a sheet portion or sheet portion with a plurality of vertical ribs extending therefrom and wherein the sheet portion or web portion and the ribs cooperate to form a plurality of U-shaped cross sections as desired. Along the length of the pallet and each U-shaped cross section has an open end, the method is characterized in that it comprises: welding a plurality of sheets or flat plastic sheets to the vertical ribs between the support columns, respectively, for completely enclosing the open ends of the U-shaped cross sections to form a plurality of section It is rectangular hollow vertical cross-sections along the length of the support rails for improved stiffness.
41. 41. The method according to claim 40, characterized in that the upper platform portion includes an upper wall with a plurality of vertical ribs extending therefrom, the method is characterized in that it further comprises welding at least one sheet or sheet of plastic to the vertical ribs on the upper platform portion to form a plurality of substantially rectangular vertical cross sections along the length of the upper platform portion for improved stiffness.
42. 42. The method according to claim 40, characterized in that the step of welding a plurality of sheets of plastic comprises sonic welding of a plurality of sheets of plastic.
43. 43. The method according to claim 40, characterized in that the plastic pallet comprises an inventory resin material having a flexural modulus of less than 14.060 Kg / square centimeter (200,000 pounds / square inch).
44. 44. A method for reinforcing a plastic pallet having a thin upper platform attached to a thin lower platform by nine support columns, wherein the thin lower platform comprises a plurality of support rails extending between the support columns, The method is characterized in that it comprises: welding a reinforcing plastic element to each of the support rails, in such a way that each reinforcement element and the respective support rail cooperate to form rectangular vertical cross sections along the length of the support rail for improved stiffness, wherein each support rail comprises a sheet portion or sheet portion and each plastic reinforcement element comprises an extruded rectangular tube that is welded to the respective sheet portion or sheet portion to form the vertical cross sections substantially rectangular.
45. 45. The method according to claim 44, characterized in that the plastic pallet comprises an inventory resin material having a flexural modulus of less than 14.060 Kg / square centimeter (200,000 pounds / square inch).
46. 46. A plastic pallet assembly or assembly, characterized in that it comprises: a platform or upper cover having an upper surface of the upper platform and a lower surface of the upper platform, spaced apart from each other and including a plurality of beam sections upper tubular disposed therein, the upper platform further includes a plurality of first column portions projecting downward from the lower surface of the upper platform and a lower platform or deck having an upper surface of the lower platform and a surface bottom of the lower platform, separated from each other and including a plurality of lower tubular beam sections disposed therein, the lower platform further includes a plurality of second column portions projecting upwardly from the upper surface of the lower platform , where the plurality of first portions of e column are joined to the plurality of corresponding second, column portions to define .TO . - column elements that extend between the upper platform and the lower platform.
47. 47. A reinforced plastic pallet, characterized in that it comprises: a sheet portion or sheet portion having a plurality of vertical ribs extending therefrom, the sheet portion or sheet portion and ribs cooperate to form a plurality of cross sections U-shaped verticals along the length of the vane and each U-shaped cross section having an open end and a plurality of flat laminar strips attached to the vertical ribs, respectively, to completely enclose the open ends of the ribs. U-shaped cross sections to form a plurality of rectangular hollow vertical cross sections along the length of the sheet portion or sheet portion for improved stiffness.