Molded pulp pallet frame

Abstract

The invention is directed to a molded pulp pallet frame for use in erecting a product display for light weight products in flexible packaging among other products.

I/We claim: 
     
         1 . A pallet frame comprising:
 a unitary body of a molded pulp material having a pair of elongate support beams extending transverse to one another at an angle from 20° to 90° and intersecting one another at an intermediate portion to form a generally x-shaped body with a planar upper surface, each support beam having opposed ends, the unitary body further having a plurality of legs extending along a line generally perpendicular to the upper surface, each leg of the plurality of legs has a wall enclosing a chamber dimensioned to receive a leg from another similarly configured unitary body to define a nesting arrangement, each leg of the plurality of legs has an opening into the chamber at one end and a ground engaging structure at an opposite end of the leg.   
     
     
         2 . The pallet frame of  claim 1  further comprising a peripheral wall connecting the plurality of legs. 
     
     
         3 . The pallet frame of  claim 2  wherein the peripheral wall has a shape selected from the group of polygonal, circular, and oval. 
     
     
         4 . The pallet frame of  claim 3  wherein the peripheral wall has a first segment and a second segment extending along a first direction and spaced from one another along a second direction transverse to the first direction, the peripheral wall further having a third segment and a fourth segment extending along the second direction, the third segment attaching one end of each of the first and second segments respectively at a first vertex and a second vertex, and the fourth segment attaching an opposed end of the first and second segments respectively at a third vertex and a fourth vertex. 
     
     
         5 . The pallet frame of  claim 4  wherein one support beam of the pair of support beams connects the first vertex to the fourth vertex, and the other support beam of the pair of support beams connects the second vertex to the third vertex. 
     
     
         6 . The pallet frame of  claim 5  wherein the polygon is a rectangle or a square. 
     
     
         7 . The pallet frame of  claim 1  further comprising a strengthening member on the x-shaped body. 
     
     
         8 . The pallet frame of  claim 7  wherein the strengthening member comprises a channel running along a portion of each of the pair of elongate support beams. 
     
     
         9 . A pallet chassis system comprising:
 a unitary body of a molded pulp material having a pair of elongate support beams extending transverse to one another at an angle from 20° to 90° and intersecting one another at an intermediate portion to form a generally x-shaped body with a planar upper surface, each support beam having opposed ends, the unitary body further having a plurality of legs extending along a line generally perpendicular to the upper surface, each leg of the plurality of legs has a wall enclosing a chamber dimensioned to receive a leg from another similarly configured unitary body to define a nesting arrangement, each leg of the plurality of legs has an opening into the chamber at one end and a ground engaging structure at an opposite end of the leg; and   a shelf tray of a corrugated sheet having an upper surface, a lower surface, and dimensioned to be placed on top of and cover an entire surface area of the planar upper surface.   
     
     
         10 . The pallet chassis system of  claim 9  wherein the shelf tray has an upstanding wall extending about a periphery of the sheet. 
     
     
         11 . The pallet chassis system of  claim 10  wherein the upstanding wall is dimensioned to engage each of the plurality of legs when the pallet chassis system is in a use condition. 
     
     
         12 . The pallet chassis system of  claim 9  wherein the polygonal shape is a rectangle or a square and has four edges and four vertexes. 
     
     
         13 . The pallet chassis of  claim 12  further comprising a peripheral wall connecting the plurality of legs. 
     
     
         14 . The pallet chassis of  claim 13  wherein the peripheral wall has a first segment and a second segment extending along a first direction and spaced from one another along a second direction transverse to the first direction, the peripheral wall further having a third segment and a fourth segment extending along the second direction, the third segment attaching one end of each of the first and second segments respectively at a first vertex and a second vertex, and the fourth segment attaching an opposed end of the first and second segments respectively at a third vertex and a fourth vertex. 
     
     
         15 . The pallet chassis of  claim 14  wherein one support beam of the pair of support beams connects the first vertex to the fourth vertex, and the other support beam of the pair of support beams connects the second vertex to the third vertex. 
     
     
         16 . A pallet chassis assembly comprising:
 a unitary body of a molded pulp material having a pair of elongate support beams extending transverse to one another at an angle from 20° to 90° and intersecting one another at an intermediate portion to form a generally x-shaped body with a planar upper surface, each support beam having opposed ends, the unitary body further having a plurality of legs extending along a line generally perpendicular to the upper surface, each leg of the plurality of legs has a wall enclosing a chamber dimensioned to receive a leg from another similarly configured unitary body to define a nesting arrangement, each leg of the plurality of legs has an opening into the chamber at one end and a ground engaging structure at an opposite end of the leg; and   a shelf tray engaging the plurality of legs and being of a corrugated sheet having an upper surface, and a lower surface.   
     
     
         17 . The assembly of  claim 16  wherein the shelf tray engages the ground engaging structure. 
     
     
         18 . The assembly of  claim 16  wherein the shelf tray engages the opening of each leg. 
     
     
         19 . The assembly of  claim 16  wherein the shelf tray has an upstanding wall about a periphery of the sheet. 
     
     
         20 . The assembly of  claim 17  further comprising a second shelf tray engaging the opening of each leg.