Integrated tray and pallet system

Abstract

The invention is directed to an integrated plastic tray and pallet system. The system includes a molded plastic pallet having an upper surface with tray components integrally formed with the remainder of the pallet extending upward from the upper surface. A plurality of pallet feet extend downward from a lower surface of the pallet. The pallet also includes side walls extending upward from the periphery of the upper surface. The system may include additional pallet and integrated tray structures without the pallet feet, and a top cap.

I claim: 
     
         1 . An integrated tray and pallet system comprising:
 a first generally rectangular pallet base having a planar upper surface; and,   a plurality of integrally formed trays having tray walls extending upward from the upper surface of the first pallet base.   
     
     
         2 . The integrated tray and pallet system of  claim 1  further comprising a plurality of feet extending downward from a bottom surface of the first pallet base. 
     
     
         3 . The integrated tray and pallet system of  claim 2  further comprising:
 a first side wall extending upward from an edge of a first side of the first pallet base; 
 a second side wall extending upward from an edge of a second side of the first pallet base; 
 a third side wall extending upward from an edge of a third side of the first pallet base; and, 
 a fourth side wall extending upward from an edge of a fourth side of the first pallet base. 
 
     
     
         4 . The integrated tray and pallet system of  claim 3  wherein each of the plurality of integrally formed trays is rectangular. 
     
     
         5 . The integrated tray and pallet system of  claim 4  wherein the plurality of integrally formed trays form an array of columns and rows. 
     
     
         6 . The integrated tray and pallet system of  claim 5  wherein the array is five by two. 
     
     
         7 . The integrated tray and pallet system of  claim 3  wherein each of the first, second, third and fourth side walls include a plurality of outwardly extending ribs. 
     
     
         8 . The integrated tray and pallet system of  claim 1  wherein the first pallet base and the plurality of integrated trays are formed from a molded plastic. 
     
     
         9 . The integrated tray and pallet system of  claim 1  further comprising:
 a second generally rectangular pallet base having a planar upper surface; and, 
 a plurality of integrally formed trays having tray walls extending upward from the upper surface of the second pallet base, the second pallet base configured to stack on the first pallet base. 
 
     
     
         10 . The integrated tray and pallet system of  claim 9  further comprising a top cap configured to be placed on top of the second pallet base. 
     
     
         11 . The integrated tray and pallet system of  claim 3  wherein the first side wall, the second side wall, the third side wall and the fourth side wall form portions of the tray wall for respective ones of the plurality of integral trays. 
     
     
         12 . An integrated tray and pallet system comprising:
 a first plastic rectangular pallet base having an upper planar support surface; and,   a first tray integrally formed with first pallet base having tray walls extending upward from the support surface.   
     
     
         13 . The integrated tray and pallet system of  claim 12  further comprising a second tray integrally formed with the first pallet base having tray walls extending upward from the support surface. 
     
     
         14 . The integrated tray and pallet system of  claim 12  further comprising a plurality of additional trays integrally formed with the first pallet base having tray walls extending upward from the support surface. 
     
     
         15 . The integrated tray and pallet system of  claim 14  wherein the first tray and the additional plurality of trays form an array of trays on the first pallet base. 
     
     
         16 . The integrated tray and pallet system of  claim 15  wherein each of the first tray and the additional plurality of trays is rectangular. 
     
     
         17 . The integrated tray and pallet system of  claim 14  having a plurality of plastic feet extending downward from a bottom surface of the first rectangular plastic pallet base. 
     
     
         18 . The integrated tray and pallet system of  claim 17  further comprising:
 a first plastic side wall extending upward from an edge of a first side of the first rectangular plastic pallet base; 
 a second plastic side wall extending upward from an edge of a second side of the first rectangular plastic pallet base; 
 a third plastic side wall extending upward from an edge of a third side of the first rectangular plastic pallet base; and, 
 a fourth plastic side wall extending upward from an edge of a fourth side of the first rectangular plastic pallet base. 
 
     
     
         19 . The integrated tray and pallet system of  claim 18  wherein each tray includes a tray wall formed from one of the first plastic side wall, the second plastic side wall, the third plastic side wall and the fourth plastic side wall. 
     
     
         20 . The integrated tray and pallet system of  claim 19  wherein each tray includes a tray wall having a first end segment, a middle segment and a second end segment wherein a height of the middle segment is less than a height of the first end segment and a height of the second end segment.