Easily assembled and repairable plastic shipping pallet

Abstract

An easily assembled and repairable plastic pallet that include two or more runner rails (FIGS. 2 & 4 ) and/with multiple plastic cross boards (FIGS. 5 & 6 ) secured perpendicularly to the opposite side rails (FIGS. 2 & 4 ). This construction allows for rapid and easy repair of a pallet (FIG. 1 ) that may become damaged. The plastic cross boards (FIGS. 5 & 6 ) and runner rails (FIGS. 2 & 4 ) are all ribbed out for the sole purpose of lighter weight. The repairable plastic pallet is made of High Density Polyethylene (HDPE) or Polypropylene (PP) in virgin or recycled material along with a foaming agent or a gas to form a stronger and lighter weight pallet. Therefore, not ruling out the uses of other types of materials possibly used in the future.

1 . This repairable plastic pallet is the first of it's kind.  
   
   
       2 . A. This pallet is made from High Density Polyethylene (HDPE) and/or Polypropylene PP), virgin or recycled material. 
 B. Also, I am using a blowing agent and/or a gas which is all blended together during the injection molding process.    C. The blowing agent or gas used in small percentage (%) makes repairable plastic pallet lighter and stronger.    D. Other forms of plastic or other materials may sometime in the future be used.    
   
   
       3 . This repairable plastic pallet consists of 2 molded parts. 1) A runner/rail ( FIG. 4 ) 
 2) board/slat ( FIGS. 5&6 ).    1 A) A runner/rail ( FIG. 4 ) is solid on both ends.    B) Ribbed out along both sides to help reduce weight. See  FIGS. 1,2  &  3 .    C) There are molded on pegs top & bottom ( FIG. 4 ) one of every 2 pegs are slightly larger (not shown in any figures) for correct board mounting.    D) There is also a molded on plastic locking device located between each pair of pegs (not seen on  FIG. 2 , but visible on  FIG. 2 -A) used to secure board/slat ( FIG. 6 ) in place.    E) The height of the molded on locking device is approximate 1/16″, which could increase or decrease.    2 A) A board/slat see  FIGS. 5 & 6 .    B) Smooth on top ( FIG. 1 ) and ribbed out on bottom ( FIG. 2 ).    C) Each board ( FIGS. 5 & 6 ) has holes which are in line with the pegs on the runners/rails ( FIG. 1 )    D) Each hole slightly larger round on each side of board/slat ( FIG. 6 ). One hole “in board/slat” is larger than the other hole “in board/slat” (not really noticeable in  FIG. 6 ) fits over head of peg. (The difference for hole sizes is for assurance of proper board mounting).    E) The slightly smaller end of each hole ( FIG. 6 ) is tapered for the head of the peg to rest in.    F) The slot for the molded on plastic locking device can be seen on top & bottom of  FIG. 5 ., but only seen from the bottom of  FIG. 6 . (Hidden).    G) Boards/slats ( FIGS. 5 & 6 ) can be mounted only in one direction.    H) After board/slat ( FIG. 6 ) is mounted, molded on locking device secures the board/slat ( FIG. 6 ) into position.    
   
   
       4 . Pallet assembled— FIG. 1 . 
 A) Illustration shows pallet assembled with notched runner/rail ( FIG. 1 ) used with a four-way entry for a forklift.    B) A straight runner can be used in the place of a notched runner/rail ( FIG. 4 ). Now the assembled pallet becomes a two-way entry pallet.    
   
   
       5 . This pallet can be shipped either assembled or unassembled depending on customers request.  
   
   
       6 . This pallet is made of 100% plastic blended with a foaming agent and/or gas. 
 A) No heat, screws and/or mechanical screws, clips, lugs, plates, flanges, hinges, bolts, nuts, nails, plastic nails, adhesives, ultra-sonic welding, or press-fitting are necessary for the assembly of this repairable plastic pallet.    B) No tools are required for assembling/disassembling of this repairable plastic pallet.    C) The only requirements needed to assemble/disassemble this repairable plastic pallet are your hands.    
   
   
       7 . This repairable plastic pallet can be repaired on the job-site, never required to be sent back to the factory for repairs.