Flex assembly of pallet base and deck

Abstract

Resin pallets having a deck and a base, where the deck and base are joined by an interlock, which is optionally reversible, are described. Methods of making such pallets by assembling the pallets by interlocking parts to form the pallets, in an optionally reversible method, are also described.

I claim: 
     
         1 . An interlock for joining bodies, the interlock comprising:
 (a) a first body including a plurality of first projections, at least two first projections including at least one first interlocking member; and   (b) a second body including:
 (i) a plurality of second interlocking members located within the second body for receiving a respective first interlocking member, or 
 (ii) a plurality of second projections, at least two second projections including at least one second interlocking member for receiving a respective first interlocking member; 
   
       wherein:
 each first interlocking member is positioned to engage with a corresponding second interlocking member when the first and second bodies are interlocked, and wherein at least one of the first body and the second body's flexibility permits at least one of tilting outward a distal portion of the second body including the second interlocking member and tilting inward a distal portion of the first projection including the first interlocking member so that a plurality of first interlocking members engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies, and 
 one of the first and second bodies is a base of a pallet and the other is a deck of a pallet. 
 
     
     
         2 . The interlock of  claim 1 , wherein at least one of the first and second bodies further comprise at least one additional projection centrally located on the element. 
     
     
         3 . The interlock of  claim 1 , wherein the first body and second body further comprise at least one additional projection centrally located on the element. 
     
     
         4 . The interlock of  claim 1 , wherein at least one of the first and second bodies are planar. 
     
     
         5 . The interlock of  claim 1 , wherein both the first and second bodies are planar. 
     
     
         6 . The interlock of  claim 1 , wherein one of the first and second bodies are planar and the other body is at least partially cambered. 
     
     
         7 . The interlock of  claim 1 , wherein one of the first and second bodies are planar and the other body is domed. 
     
     
         8 . The interlock of  claim 1 , wherein both the first and second bodies are cambered or domed. 
     
     
         9 . The interlock of  claim 1 , wherein both the first planar body and the second planar body have flexibility permitting tilting outward a distal portion of the second body including the second interlocking member and tilting inward a distal portion of the first projection including the first interlocking member so that a plurality of first interlocking members engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies. 
     
     
         10 . The interlock of  claim 1 , wherein at least one of the first body and the second body has flexibility permitting a plurality of first interlocking members to engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies. 
     
     
         11 . The interlock of  claim 1 , wherein both the first body and the second body are planar and have flexibility permitting a plurality of first interlocking members to engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies. 
     
     
         12 . The interlock of  claim 1 , wherein the second interlocking member for receiving a respective first interlocking member is angled. 
     
     
         13 . The interlock of  claim 1 , wherein at least one of the first body and the second body comprises a living hinge or a hinge. 
     
     
         14 . The interlock of  claim 1 , wherein at least one of the first body and the second body comprises a plurality of pieces. 
     
     
         15 . The interlock of  claim 14 , wherein the plurality of pieces is connected by a hinge. 
     
     
         16 . The interlock of  claim 1 , wherein the interlock allows the first and second bodies to be disconnected without damaging either the first or second element. 
     
     
         17 . A method of interlocking bodies having interlocks to form a pallet, the method comprising:
 (a) providing:
 (i) a first body including a plurality of first projections, at least two of the first projections including at least one first interlocking member; and 
 (ii) a second body including a plurality of second projections, at least two of the second projections including at least one second interlocking member for receiving a respective first interlocking member; 
   
       wherein:
   each second projection is positioned to engage with a corresponding first projection when the first and second bodies are interlocked, and at least one of the first body and the second body has flexibility permitting at least one of tilting outward a distal portion of the second projection including the second interlocking member and tilting inward a distal portion of the first projection including the first interlocking member so that a plurality of first interlocking members engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies,   
 (b) flexing a bendable portion of at least one of the first body and the second body by applying force against the body to flex the body, wherein at least one of the first body and the second body tilts outward a distal portion of the second projection including the second interlocking member and tilts inward a distal portion of the first projection including the first interlocking member, 
 (c) applying sufficient force to allow a plurality of first interlocking members to engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies, 
 (d) removing the force and allowing the first body and the second body to return to an unflexed state wherein the first and second bodies are interlocked, wherein one of the first and second bodies is a base of a pallet and the other is a deck of a pallet. 
 
     
     
         18 . The method of  claim 17 , where step b comprises cambering the first body and the second body by placing a force against the bodies to flex the bodies and wherein the first body and the second body tilt outward a distal portion of the second projection including the second interlocking member and tilt inward a distal portion of the first projection including the first interlocking member, wherein the amount of force applied allows a plurality of first interlocking members to engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies. 
     
     
         19 . The method of  claim 17 , wherein first and second bodies are interlocked by sliding the first and second bodies horizontally with respect to each other to achieve engagement of the at least one first interlocking member with the at least one second interlocking member. 
     
     
         20 . A method of disassembling a plurality of bodies connected by interlocks, the method comprising:
 (a) providing an assembly comprising a first body and a second body interconnected by an interlock, the assembly comprising :
 (i) a first body including a plurality of first projections positioned along a perimeter of the first body, at least two of the first projections including at least one first interlocking member; and 
 (ii) a second body including a plurality of second projections, at least two of the second projections including at least one second interlocking member for receiving a respective first interlocking member; 
   
       wherein:
   each second projection is positioned to engage with a corresponding first projection when the first and second bodies are interlocked, and at least one of the first body and the second body flex for at least one of tilting outward a distal portion of the second projection including the second interlocking member and tilting inward a distal portion of the first projection including the first interlocking member so that a plurality of first interlocking members engage a plurality of corresponding second interlocking members on opposing sides of the first and second bodies,   
 (b) cambering at least one of the first body and the second body by applying force against the body to flex the body, wherein at least one of the first body and the second body tilts outward a distal portion of the second projection including the second interlocking member and tilts inward a distal portion of the first projection including the first interlocking member, 
 (c) applying sufficient force to allow a plurality of first interlocking members to disengage from a plurality of corresponding second interlocking members on opposing sides of the first and second bodies, 
 (d) removing the force and allowing the first body and the second body to return to an unflexed state wherein the first and second bodies are disengaged, wherein one of the first and second bodies is a base of a pallet and the other is a deck of a pallet. 
 
     
     
         21 . The method of  claim 20 , where step b comprises cambering the first body and the second body by placing a force against the bodies to flex the bodies wherein the first body and the second body tilt outward a distal portion of the second projection including the second interlocking member and tilt inward a distal portion of the first projection including the first interlocking member, wherein the amount of force applied allows a plurality of first interlocking members to disengage from a plurality of corresponding second interlocking members on opposing sides of the first and second bodies. 
     
     
         22 . An interlock for joining bodies, the interlock comprising:
 a) at least a first body and a second body, wherein at least one of the first and second bodies are flexible to allow at least one first interlocking element on the first body to engage with at least one respective second interlocking element on the second body;   b) wherein at least one of the first and second interlocking elements rotates inward or outward relative to the other interlock element to allow engagement of the first interlocking element on one of the bodies with the respective second interlocking element on the other of the bodies;   c) wherein an interlock formed between the at least one first interlocking and second interlocking elements is maintained when e at least one of the bodies, after being flexed, is returned to an unflexed state; and   d) wherein, when the at least one first interlocking and second interlocking elements are engaged, the first and second bodies form at least a portion of a pallet.   
     
     
         23 . A method of interlocking bodies having interlocks to form a pallet, the method comprising:
 (a) providing:
 i) at least a first body and a second body, wherein at least one of the first body and the second body are flexible to allow at least one first interlocking element on the first body to engage with at least one respective second interlocking element on the second body; 
 ii) wherein at least one of the first and second interlocking elements rotates inward or outward relative to the other interlocking element to allow engagement of the first interlocking element on one of the bodies with the respective second interlocking element on the other of the bodies; 
 iii) wherein an interlock formed between the at least one first and second interlocking elements is maintained when at least one of the bodies, after being flexed, is returned to an unflexed state; and 
 iv) wherein, when the at least one first and second interlocking elements are engaged, the first and second bodies form at least a portion of a pallet, 
   (b) flexing a bendable portion of at least one of the first body and the second body by applying force against the body to flex the body, wherein at least one of the first and second bodies tilt outward a distal portion of the second body including the second interlocking element and tilts inward a distal portion of the first body including the first interlocking element,   (c) applying sufficient force to allow a first interlocking element to engage a corresponding second interlocking element on opposing sides of the first and second bodies,   (d) removing the force and allowing at least one of the first body and the second body to return to an unflexed state wherein the first and second bodies are interlocked, wherein one of the first and second bodies is a base of a pallet and the other is a deck of a pallet.   
     
     
         24 . The method of  claim 23 , where step b comprises cambering the first body and the second body by placing a force against the bodies to flex the bodies and wherein the first body and the second body tilt outward a distal portion of the second body including the second interlocking element and tilt inward a distal portion of the first body including the first interlocking element, wherein the amount of force applied allows a first interlocking element to engage a corresponding second interlocking element on opposing sides of the first and second bodies. 
     
     
         25 . The method of  claim 23 , wherein first and second bodies are interlocked by sliding the first and second bodies horizontally with respect to each other to achieve engagement of the at least one first interlocking element with the at least one second interlocking element. 
     
     
         26 . A method of disassembling a plurality of bodies connected by an interlock, the method comprising:
 (a) providing an assembly comprising a first body and a second body interconnected by an interlock, the assembly comprising :
 i) at least a first body and a second body, wherein at least one of the first body and the second body are flexible to allow at least one first interlocking element on the first body to engage with at least one respective second interlocking element on the second body; 
 ii) wherein at least one of the first and second interlocking elements rotates inward or outward relative to the other interlocking element to allow engagement of the first interlocking element with the respective second interlock element; 
 iii) wherein an interlock formed between the at least one first and second interlocking elements is maintained when at least one of the bodies, after being flexed, is returned to an unflexed state; and 
 iv) wherein, when the at least one first and second interlocking elements are engaged, the first and second bodies form at least a portion of a pallet, 
   (b) cambering at least one of the first body and the second body by applying force against the body to flex the body, wherein at least one of the first body and the second body tilts outward a distal portion of the second body including the second interlocking element and tilts inward a distal portion of the first body including the first interlocking elements,   (c) applying sufficient force to allow a plurality of first interlocking elements to disengage from a plurality of corresponding second interlocking elements on opposing sides of the first and second bodies,   (d) removing the force and allowing at least one of the first body and the second body to return to an unflexed state wherein the first and second bodies are disengaged.   
     
     
         27 . The method of  claim 26 , where step b comprises cambering the first body and the second body by placing a force against the bodies to flex the bodies and wherein the first body and the second body tilt outward a distal portion of the second body including the second interlocking member and tilt inward a distal portion of the first body including the first interlocking member, wherein the amount of force applied allows a first interlocking member to disengage from a corresponding second interlocking member on opposing sides of the first and second bodies.