Interlocking modular tubular pallet

Abstract

The invention pertains to the design of polymer or molded part that can be used for pallets or decking material. A pallet having a plurality of pallet sections each composed of interlocking tubular elements defined by top and bottom surfaces. The interlocking find overlapping sections provide a continuous surface in immovable assembly. The edge of the top surface of one tubular section has a flange that protrudes from it that fits in a corresponding groove of an adjacent tubular section so as to provide a flat connected surface. At least two tubular elements are located next to one another with collinear edges and are oriented in the same direction to support loads on top and bottom surfaces and resist bending. The modular design of the tubular sections allows for the continuous structure to be divided into several regions for ease of repair or serviceability.

I claim:  
     
         1 . A method for manufacture of tubular pallet, comprising: 
 (a) forming a plurality of tubular pallet sections each being of generally cross-sectional configuration and having spaced upper and lower walls and spaced side walls, at least two of said upper and lower walls of each of said tubular interlocking sections being top and bottom walls defining the flange of one section intersecting the groove of the neighboring section extending the length of the respective top and bottom wall; and    (b) establishing interlocking assembly of said interlocking sections for securing top and bottom walls of said plurality of pallet sections in interlocked assembly.    
     
     
         2 . The method of  claim 1 , further comprising, 
 during forming, establishing a pair of spaced generally parallel top and bottom walls interconnected by top and bottom walls and forming said interlocking sections being located on said top walls, bottom walls, or both top and bottom walls.    
     
     
         3 . The method of  claim 1 , further comprising, 
 after establishing interlocking assembly of said interlocking sections, securing said interlocking sections in permanent and immovable assembly.    
     
     
         4 . The method of  claim 3 , further comprising, 
 adhesive bonding of said interlocking sections.    
     
     
         5 . The method of  claim 3 , further comprising, 
 thermal welding of said interlocking sections.    
     
     
         6 . The method of  claim 3 , further comprising, 
 mechanically fastening of said interlocking sections.    
     
     
         7 . A pallet, comprising: 
 (a) a plurality of tubular interlocking pallet sections each being of generally cross-sectional configuration and having spaced upper and lower walls and spaced side walls, at least two of said upper and lower walls of each of said tubular interlocking sections being top and bottom walls defining the flange of one section intersecting the groove of the neighboring section extending the length of the respective top and bottom wall;    (b) at least two tubular elements are located next to one another with collinear edges and are oriented in the same direction to support loads on top and bottom surfaces and resist bending; and    (c) at least one cross-member tubular section with flanges on the top and bottom walls of the right and left sides.    
     
     
         8 . The pallet of  claim 7 , further comprising: 
 (a) said interlocking sections being a protruding flange and corresponding channel groove defined by adjacent pallet sections;    (b) said interlocking sections being disposed in mechanically interlocked assembly;    (c) said interlocking sections being disposed in adhesive bonding interlocked assembly; and    (d) said interlocking sections being disposed in heat welded interlocked assembly.    
     
     
         9 . The pallet of  claim 7 , further comprising: 
 (a) each of said pallet sections defining a planar top and bottom walls and said spaced side walls having substantially parallel relation and being oriented in substantially perpendicular with said planar top and bottom walls;    (b) said top and bottom walls of adjacent pallet sections defining said interlocking elements; and    (c) said interlocking elements securing top and bottom walls of adjacent pallet sections in interlocked assembly and orienting said planar top walls of said pallet sections in substantially co-planar relation.    
     
     
         10 . The pallet of  claim 9 , further comprising: 
 (a) each of said tubular pallet sections being of integral construction and said top and bottom walls being of planar configuration and being disposed in substantially parallel relation, said spaced walls being disposed in substantially parallel relation and being oriented in substantially perpendicular relation with said planar top wall and said planar bottom wall;    (b) said top and bottom walls of adjacent pallet sections defining said interlocking elements; and    (c) said interlocking sections securing top and bottom walls of adjacent pallet section in interlocked assembly and orienting said planar top walls of each of said pallet sections in substantially co-planar relation and orienting said planar bottom walls of each said pallet sections in substantially co-planar relation.