Blow molded pallet with wave-like supports

Abstract

A pallet system has a pallet body that includes a first portion with an outer surface and an inner surface that has at least a portion distant from the outer surface and a corrugating form. The pallet body also includes a second portion with an outer surface and an inner surface that has at least a portion distant from the outer surface and a corrugating form. The inner surface of the first portion is connected to the inner surface of the second portion between each respective corrugating form. Channels and protrusions may also be used to add strength and support to the body. The portions are connected at tack off points.

What is claimed is:  
     
         1 . A pallet comprising: 
 a first portion having an outer surface and an inner surface at least a portion of which is distant the outer surface; and    a second portion having an outer surface and an inner surface at least a portion of which is distant the outer surface, wherein the inner surface of the first portion indigitates with the inner surface of the second portion.    
     
     
         2 . The pallet of  claim 1  wherein the inner surface of the first portion and the inner surface of the second portion comprise complementarily shaped surfaces.  
     
     
         3 . The pallet of  claim 1  wherein the inner surfaces of the first and second portions each have an undulating form.  
     
     
         4 . The pallet of  claim 1  wherein inner surfaces of the first and second portions each comprise a succession of curved protrusions.  
     
     
         5 . The pallet of  claim 1  wherein the outer surface of the second portion comprises at least two segments that are closer to the first portion than the remainder of the second portion.  
     
     
         6 . The pallet of  claim 1  wherein the outer surface of the second portion comprises at least two feet.  
     
     
         7 . The pallet of  claim 1  wherein the outer surface of the second portion comprises a series of ridges and grooves.  
     
     
         8 . The pallet of  claim 7  wherein the inner surfaces of the first and second portions each comprise a succession of curves having rises and falls that run perpendicular to the series of ridges and grooves on the outer surface of the second portion and further comprising tine accepting channels in the second portion.  
     
     
         9 . The pallet of  claim 1  wherein the outer surface of the first portion is generally planar.  
     
     
         10 . The pallet of  claim 1  wherein: a) the inner surface of the first portion is molded to the inner surface of the second portion; b) the pallet is formed from puncture-resistant plastics; and c) tack off points are located along peaks and valleys of the portions  
     
     
         11 . A pallet comprising: 
 a pallet body including:    a first portion having an outer surface and an inner surface having at least a portion of which that is distant the outer surface and having a corrugating form; and    a second portion having an outer surface and an inner surface having at least a portion of which that is distant the outer surface and having a corrugating form,    wherein the inner surface of the first portion is connected to the inner surface of the second portion between each respective corrugating form.    
     
     
         12 . A pallet of  claim 11  wherein the inner surface of the first portion is molded to the inner surface of the second portion.  
     
     
         13 . A method of forming a pallet comprising the steps of: 
 a) blow molding a first portion having an outer surface and an inner surface at least a portion of which is distant the outer surface; and    b) blow molding a second portion having an outer surface and an inner surface at least a portion of which is distant the outer surface around the first portion.    
     
     
         14 . A method of  claim 13  wherein one of the first portion and the second portion is inserted into a mold shaping the other one of the first portion and the second portion prior to the blow molding of the other one of the first portion and the second portion.  
     
     
         15 . A blow-molded pallet comprising: 
 a) a bottom portion having a first bottom surface and a first top surface wherein said top surface has a first set of channels and protrusions;    b) an upper portion having a second top surface and a second bottom surface having a second set of channels and protrusions; and    wherein the second set of channels and protrusions of the upper portion interlock with the first set of protrusions and channels respectively of the bottom portion.    
     
     
         16 . The pallet of  claim 15 , wherein the upper portion and the bottom portion are fused by applying heat to one of the portions and pressing the two portions together.  
     
     
         17 . The pallet of  claim 15 , wherein at least one portion contains cavities and wherein the other portion contains an extending member which is inserted into the cavity during molding to lock one portion to another portion.  
     
     
         18 . The pallet of  claim 15 , wherein one portion contains a locking member, and wherein the other portion contains a receiving member so that the locking member and receiving member communicate to lock one portion to the other portion.  
     
     
         19 . The pallet of  claim 15 , wherein one portion has at least one tack off point which allows the upper portion to become attached to the bottom portion.  
     
     
         20 . The pallet of  claim 15 , wherein the upper portion includes at least one leg; and wherein the bottom portion includes one foot having a hollow portion for receiving a foot of the upper portion.  
     
     
         21 . The pallet of  claim 15 , further comprising an upper portion first end and an upper portion second end included with the upper portion; and a bottom portion first end and a bottom portion second end included with the bottom portion, wherein at least the upper first end mates with the bottom first end.  
     
     
         22 . The pallet of  claim 15 , wherein the upper portion and the bottom portion are fused during molding.  
     
     
         23 . The pallet of  claim 15 , further comprising a) a lip extending from the pallet; b) radiused corners on edges of the pallet; and c) a third blow molded portion.