Rackable composite shipping pallet for transporting and storing loads

Abstract

A rackable pallet is disclosed that has a load bearing deck, a plurality of cross beams, and a plurality of removable base supports connected approximately perpendicular to the cross beams, and is made of a polymer. One disclosed pallet is open from the bottom and particularly suited for use in large automated warehouses, where machinery lifts and moves pallets by remote control. In one embodiment the pallet comprises a support structure that comprises a plurality of cross beams and a plurality of base supports connected to the cross beams. The deck and the cross beams typically define a single, injection-molded piece of polymer material. The base supports may be removable for repair or replacement. In one embodiment the load bearing deck has a plurality of domes in an array that provide high strength, stiffness, and rigidity.

1 . A pallet for holding and transporting materials comprising: 
 a rigid deck that has an upper and a lower surface and a plurality of arch elements configured with their top peaks proximate to the upper surface, said deck including a plurality of adjacent arch elements situated in an intersecting configuration such that downward forces from a load applied to the upper surface of said deck are distributed from the top of said arches downwardly through each of said arch elements and laterally towards adjacent arch elements, such that forces from adjacent arch elements intersect each other to provide lateral compressive forces to strengthen said deck; and    a support structure extending from said lower surface of said deck, comprising: 
 a plurality of cross beams connected to said lower surface of said deck, said cross beams arranged approximately parallel to each other, each of said cross beams comprising a plurality of downwardly-facing openings; and  
 a plurality of base supports connected to said cross beams, said cross beams having an upwardly-extending section that has a configuration for engaging with said openings in said cross beams, said base supports arranged approximately parallel to each other and approximately perpendicular to said cross beams.  
   
   
   
       2 . The pallet of  claim 1  wherein said deck and said cross beams define a single, injection-molded piece of polymer material.  
   
   
       3 . The pallet of  claim 1  wherein said base supports are removably engaged with said cross beams.  
   
   
       4 . The pallet of  claim 1  wherein each of said plurality of base supports is substantially identical and thereby interchangeable.  
   
   
       5 . The pallet of  claim 1 , wherein said plurality of base supports define an approximately flat bottom surface for resting on a flat surface.  
   
   
       6 . The pallet of  claim 1  wherein said cross beams comprise a plurality of transverse and longitudinal ribs arranged in an intersecting configuration.  
   
   
       7 . The pallet of  claim 1  comprising three cross beams and three base supports that intersect said cross beams at approximately 90°.  
   
   
       8 . The pallet of  claim 1 , wherein said cross beams, said base supports are configured to define spacing to receive at least one of a forklift, pallet jack, hand truck, and automated lifting machinery.  
   
   
       9 . The pallet of  claim 1  wherein said upwardly-extending section of said base supports and the portion of the cross beams surrounding said opening define a plurality of posts, and said plurality of posts are situated to define spacing between said posts dimensioned to receive at least one of a forklift, pallet jack, hand truck, and automated lifting machinery.  
   
   
       10 . The pallet of  claim 1 , wherein said plurality of arch elements comprise a plurality of rows of said arch elements, said plurality of rows extending in at least two directions that cross each other at a non-zero angle.  
   
   
       11 . A pallet for supporting a load, comprising: 
 a load bearing deck that defines an upper surface for receiving said load and a lower surface opposite said upper surface, said load bearing deck comprising a plurality of domes, each dome defined by an apex located proximate to said upper surface and a plurality of legs extending from said apex and ending at said lower surface, said domes arranged in an array including a plurality of adjacent domes such that a load applied substantially to said dome apexes will be transmitted substantially laterally along said legs to produce intersecting compressive forces between adjacent domes; and    a support structure extending from said lower surface of said deck, comprising: 
 a plurality of cross beams connected to said lower surface of said deck, said cross beams arranged approximately parallel to each other, each of said cross beams comprising a plurality of downwardly-facing openings; and  
 a plurality of base supports connected to said cross beams, said cross beams having an upwardly-extending section that has a configuration for engaging with said openings in said cross beams, said base supports arranged approximately parallel to each other and approximately perpendicular to said cross beams.  
   
   
   
       12 . The pallet of  claim 11  wherein said deck and said cross beams define a single, injection-molded piece of polymer material.  
   
   
       13 . The pallet of  claim 11  wherein said base supports are removably engaged with said cross beams.  
   
   
       14 . The pallet of  claim 11  wherein each of said plurality of base supports is substantially identical and thereby interchangeable.  
   
   
       15 . The pallet of  claim 11 , wherein said plurality of base supports define an approximately flat bottom surface for resting on a flat surface.  
   
   
       16 . The pallet of  claim 11  comprising three cross beams and three base supports that intersect said cross beams at approximately 90°.  
   
   
       17 . The pallet of  claim 11 , wherein said cross beams, said base supports are configured to define spacing to receive at least one of a forklift, pallet jack, hand truck, and automated lifting machinery.  
   
   
       18 . The pallet of  claim 11 , wherein a plurality of said domes comprise a closed dome structure.  
   
   
       19 . The pallet of  claim 11 , wherein at least some of said domes comprise an open dome structure defined by a plurality of arches having apexes that define said dome apex and two legs extending from each of said arch apexes that define said dome legs, thereby forming open areas between said dome legs.  
   
   
       20 . The pallet of  claim 11 , wherein said plurality of domes are situated in a plurality of dome rows that extend in at least two directions and intersect each other at a non-zero angle to form a pattern.