Reduced profile, improved-strength, improved-ridgity, plastic one-way pallet

Abstract

A plastic pallet is thermoformed from a sheet of light-weight plastic material having a reduced thickness or gauge relative to conventional plastic pallets and is lighter than correspondingly-sized wood and conventional plastic pallets. The pallet includes support legs that give the pallet a profile height that is less than that of a correspondingly-sized wood or plastic pallet. The support legs have a variety of different sizes and/or shapes, such as rectangular or annular. The support legs are generally evenly distributed over the surface of the pallet and can include one or more pairs of protrusions. The total support leg area is generally larger than a conventional similarly-sized plastic pallet, while the area within each individual support leg opening is generally smaller than a similarly-sized conventional plastic pallet. Items on the plastic pallet that extend over a support leg will be better supported due to the reduced size and/or protrusions.

1 . A pallet, comprising: 
 a support deck made of a first material;    a plurality of support structures extending away from the support deck and formed of the first material, each of the plurality of support structures extending to a surface on which the pallet rests, comprising:    a first plurality of the support structures positioned around the periphery of the pallet, each of the first plurality of support structures having a pair of projections extending into the support structure from opposite side walls of that support structure, each of the protrusions extending from the support deck to a bottom surface of the support structure, and    at least one additional support structure that forms a generally annular support in a central region of the pallet, each additional support structure having at least one pair of protrusions, each pair of protrusions extending from opposite side walls of the additional support structure into the interior of the additional support structure and meeting each other in the interior of the support structure, a connection formed between that pair of protrusions in the interior of that additional support structure, the protrusions extending at least part way up the sides of that additional support structure from a bottom surface of that additional support structure.    
   
   
       2 . The pallet of  claim 1 , wherein the plurality of support structures further includes a central support structure formed within the bounds of the annular support.  
   
   
       3 . The pallet of  claim 1 , wherein the first plurality of support structures positioned around the periphery of the pallet includes: 
 at least one first support structure, having at least one of a first size and a first shape; and    at least one second support structure having at least one of a second size that is different from the first size and a second shape that is different from the first shape.    
   
   
       4 . The pallet of  claim 3 , wherein the first plurality of support structures positioned around the periphery of the pallet further includes at least one third support structure having at least one of a third size that is different from at least one of the first and second sizes and a third shape that is different from at least one of the first and second shapes.  
   
   
       5 . The pallet of  claim 4 , wherein the first plurality of support structures positioned around the periphery of the pallet further includes a fourth support structure having at least one of a fourth size that is different from at least one of the first, second and third sizes and a fourth shape that is different from at least one of at least the first, second and third shapes.  
   
   
       6 . The pallet of  claim 3 , wherein each at least one first support structure has a pair of main protrusions extending from opposing walls into the interior of that first support structure and a pair of secondary protrusions that extend from the main protrusions and that meet each other in the interior of the first support structure, a connection formed between that pair of secondary protrusions in the interior of that first support structure  
   
   
       7 . The pallet of  claim 6 , wherein each at least one second support structure that has at least one of a second size that is different from the first size and a second shape that is different from the first shape does not have a pair of secondary protrusions.  
   
   
       8 . The pallet of  claim 6 , wherein each at least one second support structure has a pair of main protrusions extending from opposing walls into the interior of that second support structure and a pair of secondary protrusions that extend from the main protrusions and that meet each other in the interior of the second support structure, a connection formed between that pair of secondary protrusions in the interior of that second support structure.  
   
   
       9 . The pallet of  claim 3 , wherein the at least one first support structure comprises at least four first support structures, one first support structure located at each corner of the pallet.  
   
   
       10 . The pallet of  claim 9 , wherein the at least one second support structure comprises a plurality of second support structures, at least one second support structure located on each of two opposing sides of the pallet between the first support structures located at the corners of the pallet.  
   
   
       11 . The pallet of  claim 10 , wherein the plurality of second support structures comprises a plurality of second support structures located on each of the two opposing sides.  
   
   
       12 . The pallet of  claim 11 , wherein the plurality of second support structures located on each of the two opposing sides comprises at least three second support structures located on each of the two opposing sides.  
   
   
       13 . The pallet of  claim 12 , wherein: 
 the first plurality of support structures positioned around the periphery of the pallet further includes at least one third support structure having at least one of a third size that is different from at least one of the first and second sizes and a third shape that is different from at least one of the first and second shapes; and    the at least one third support structure comprises a plurality of third support structures, at least one third support structure located on each of a second pair of two opposing sides of the pallet, the second pair being different from the two opposing sides on which the second support structures are located, the third support structures located between the first support structures located at the corners of the pallet.    
   
   
       14 . The pallet of  claim 13 , wherein the plurality of third support structures comprises a plurality of the support structures located on each of a second pair of two opposing sides.  
   
   
       15 . The pallet of  claim 14 , 
 the first plurality of support structures positioned around the periphery of the pallet further includes at least one fourth support structure having at least one of a fourth size that is different from at least one of the first, second and third sizes and a fourth shape that is different from at least one of the first, second and third shapes; and    the at least one fourth support structure comprises a plurality of fourth support structures, at least one fourth support structure located on each of the second pair of two opposing sides of the pallet, the fourth support structures located between the first support structures located at the corners of the pallet.    
   
   
       16 . The pallet of  claim 15 , wherein the fourth support structures are located between the plurality of third support structures located along that second pair of two opposing sides of the pallet.  
   
   
       17 . The pallet of  claim 1 , wherein: 
 the support deck has a first area;    each of the plurality of support structures defines a cavity having an area; and    a total area of the cavities is about 20% to about 35% of the first area.    
   
   
       18 . The pallet of  claim 17 , wherein the area of the cavity of each of the plurality of support structures is about 0.5% to about 12% of the first area.  
   
   
       19 . (canceled)  
   
   
       20 . (canceled)  
   
   
       21 . (canceled)  
   
   
       22 . (canceled)  
   
   
       23 . (canceled)  
   
   
       24 . (canceled)  
   
   
       25 . The pallet of  claim 1 , wherein a total profile height of the pallet is about 3 inches to about 3.5 inches.  
   
   
       26 . A pallet, comprising: 
 a support deck made of a first material; and    a plurality of support structures extending away from the support deck and formed of the first material, each of the plurality of support structures extending to a surface on which the pallet rests, wherein at least some of the plurality of support structures have a pair of protrusions extending from opposing walls into the interior of that support structure, the protrusions forming portions of the support deck.    
   
   
       27 . The pallet of  claim 26 , wherein the plurality of support structures comprises: 
 a first subset of the plurality of support structures that have the pair of protrusions; and    a second subset of the plurality of support structures that lack the pair of protrusions.    
   
   
       28 . The pallet of  claim 27 , wherein each of at least some of the first subset of the plurality of support structures comprises at least one pair of second protrusions that extend from the protrusions and that meet each other in the interior of that support structure, wherein, for each pair of second protrusions, a connection is formed between that pair of second protrusions in the interior of that support structure.  
   
   
       29 . The pallet of  claim 27 , wherein the first subset of the plurality of support structures comprises 
 a first sub-subset of the first subset of the plurality of support structures that have the at least one pair of second protrusions; and    a second sub-subset of the first subset of the plurality of support structures that lack the at least one pair of second protrusions.    
   
   
       30 . The pallet of  claim 29 , wherein, in each of the second sub-subset of the first subset of the plurality of support structures, the protrusions extending from opposing walls into the interior of that support structure are spaced from each other.  
   
   
       31 . The pallet of  claim 29 , wherein each of at least some of the second subset of the plurality of support structures comprises at least one pair of second protrusions that extend from opposing walls into the interior of that support structure and that meet each other in the interior of that support structure, wherein, for each pair of second protrusions, a connection is formed between that pair of second protrusions in the interior of that support structure.  
   
   
       32 . The pallet of  claim 28 , wherein the protrusions extend into the support structure a distance that is at least about 10% of the distance between the walls from which the protrusions extend.  
   
   
       33 . The pallet of  claim 32 , wherein the second protrusions extend the remaining distance between the walls from which the protrusions extend.  
   
   
       34 . The pallet of  claim 32 , wherein the protrusions extend into the support structure a distance that is at most about 40% of the distance between the walls from which the protrusions extend.  
   
   
       35 . The pallet of  claim 28 , wherein the protrusions extend into the support structure a distance that is at most about 40% of the distance between the walls from which the protrusions extend.  
   
   
       36 . The pallet of  claim 27 , wherein the second subset of the plurality of support structures comprises 
 a first sub-subset of the second subset of the plurality of support structures that have the at least one pair of second protrusions; and    a second sub-subset of the second subset of the plurality of support structures that lack the at least one pair of second protrusions.    
   
   
       37 . The pallet of  claim 36 , wherein, in each of the second sub-subset of the second subset of the plurality of support structures, the second protrusions do not extend to the support deck.  
   
   
       38 . The pallet of  claim 26 , wherein the plurality of support structures comprises at least one support structure that forms a generally annular support in a central region of the pallet, each at least one support structure having at least one pair of second protrusions, each pair of second protrusions extending from opposite walls of that support structure into the interior of that support structure and meeting each other in the interior of that support structure, a connection formed between that pair of protrusions in the interior of that support structure.  
   
   
       39 . The pallet of  claim 38 , wherein the plurality of support structures further comprises a central support structure formed within the bounds of the generally annular support.  
   
   
       40 . The pallet of  claim 38 , wherein, for each pair of second protrusions of a particular support structure, the pair of second protrusions extend at least part way up the sides of that support structure from a bottom surface of that support structure.  
   
   
       41 . The pallet of  claim 38 , wherein the plurality of support structures further comprise a plurality of the support structures arranged around the at least one support structure that forms the generally annular support.  
   
   
       42 . The pallet of  claim 38 , wherein the at least one support structure that forms a generally annular support comprises a single continuous support structure.  
   
   
       43 . The pallet of  claim 42 , wherein the single continuous support structure is a rectangular annulus support structure.  
   
   
       44 . The pallet of  claim 26 , wherein: 
 the support deck has a first area;    each of the plurality of support structures defines a cavity having an area; and    a total area of the cavities is about 20% to about 35% of the first area.    
   
   
       45 . The pallet of  claim 44 , wherein the area of the cavity of each of the plurality of support structures is about 0.5% to about 12% of the first area.  
   
   
       46 . (canceled)  
   
   
       47 . (canceled)  
   
   
       48 . (canceled)  
   
   
       49 . (canceled)  
   
   
       50 . (canceled)  
   
   
       51 . (canceled)  
   
   
       52 . The pallet of  claim 26 , wherein a total profile height of the pallet is about 3 inches to about 3.5 inches.  
   
   
       53 . A pallet, comprising: 
 a support deck made of a first material;    a plurality of support structures extending away from the support deck and formed of the first material, each of the plurality of support structures extending to a surface on which the pallet rests, comprising:    a first plurality of the support structures positioned around the periphery of the pallet, each of the first plurality of support structures having a plurality of projections extending into the support structure from opposite side walls of that support structure, each of the protrusions extending from the support deck to a bottom surface of the support structure,    at least one additional support structure that forms a generally annular support in a central region of the pallet, each additional support structure having a plurality of protrusions, the protrusions extending at least part way up the sides of that additional support structure from a bottom surface of that additional support structure, the plurality of protrusions extending from opposite side walls of the additional support structure into the interior of the additional support structure, and    a central support structure formed within the bounds of the annular support.    
   
   
       54 . The pallet of  claim 53 , wherein the first plurality of support structures positioned around the periphery of the pallet includes: 
 at least one first support structure, having at least one of a first size and a first shape; and    at least one second support structure having at least one of a second size that is different from the first size and a second shape that is different from the first shape.    
   
   
       55 . The pallet of  claim 54 , wherein the at least one first support structure comprises at least four first support structures, one first support structure located at each corner of the pallet.  
   
   
       56 . The pallet of  claim 55 , wherein the at least one second support structure comprises a plurality of second support structures, at least one second support structure located on each of two opposing sides of the pallet between the first support structures located at the corners of the pallet.  
   
   
       57 . The pallet of  claim 56 , wherein the plurality of second support structures comprises a plurality of second support structures located on each of the two opposing sides.  
   
   
       58 . The pallet of  claim 57 , wherein the plurality of second support structures located on each of the two opposing sides comprises at least three second support structures located on each of the two opposing sides. pallet.  
   
   
       59 . The pallet of  claim 53 , wherein: 
 the support deck has a first area;    each of the plurality of support structures defines a cavity having an area; and    a total area of the cavities is about 20% to about 35% of the first area.    
   
   
       60 . The pallet of  claim 59 , wherein the area of the cavity of each of the plurality of support structures is about 0.5% to about 12% of the first area.  
   
   
       61 . The pallet of  claim 53 , wherein a total profile height of the pallet is about 3 inches to about 3.5 inches.  
   
   
       62 . The pallet of  claim 53 , wherein the at least one support structure that forms a generally annular support comprises a single continuous support structure.  
   
   
       63 . The pallet of  claim 1 , wherein the at least one support structure that forms a generally annular support comprises a single continuous support structure.  
   
   
       64 . The pallet of  claim 63 , wherein the single continuous support structure is a rectangular annulus support structure.