MULTI-FUNCTIONAL PALLET

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/734,880, entitled “MULTI-FUNCTIONAL PALLET FOR ENHANCED LOAD STABILITY AND OPERATIONAL EFFICIENCY,” filed on Dec. 17, 2024, the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present disclosure relates generally to pallets for material handling, storage, and distribution. More particularly, it relates to a pallet formed by twin-sheet thermoform plastic, injection mold plastic, or hybrid composites and configured to provide enhanced load stability and improved maneuverability while maintaining compatibility with standard manual and automated handling equipment.

2. Description of Related Art

Conventional pallets, whether constructed from wood, injection-molded plastic, or hybrid composites, often present significant tradeoffs among durability, hygiene, weight, cost, and maneuverability. Wooden pallets remain widely used because of their low initial cost, but they are prone to splintering, nail protrusion, and dimensional variability due to moisture absorption and warping. These characteristics create safety hazards, reduce service life, and compromise compatibility with automated storage and retrieval systems. Wood pallets can also harbor bacteria, mold, and pests, making them unsuitable for hygienic environments such as food, beverage, and pharmaceutical logistics.

Many current pallet designs address some of these hygiene concerns but can often be heavier and more expensive to produce, particularly in larger footprints. Impact loading can cause cracks or permanent deformation that reduces load-bearing capacity and can render the pallet unsafe for reuse. Further, once damaged, repair is typically impractical, leading to waste and higher replacement costs.

Typical industry-standard design footprints, such as 40 inches by 48 inches, may be efficient for warehousing but limit maneuverability in narrow retail aisles, cooler doorways, and last-mile delivery environments. Certain smaller footprint designs allow for more efficient receiving process with retailers because all product can be scanned from the exterior of the pallet. This removes the step of unstacking product for retailers to confirm receipt of each SKU (stock keeping unit). Smooth or untextured deck surfaces on many pallets can cause supported goods to shift during forklift transport or automated stretch wrapping, increasing the risk of load instability.

Many conventional designs are not optimized for modern automated handling systems such as chain-driven wrap machines, conveyorized material-handling lines, or robotic palletizers. Misalignment, excessive deck deflection, or lack of standardized runner geometry can cause jams, downtime, and equipment damage. Additionally, sustainability concerns have increased pressure to move away from single-use wood pallets or heavy non-recyclable plastics toward designs that allow for high recycled content, end-of-life recyclability, and reduced material use without sacrificing structural performance.

There therefore remains a need for a pallet that combines reduced weight with durability, dimensional stability, and compatibility with automated systems. Such a pallet should improve maneuverability in constrained environments, increase load stability during wrapping and transport, reduce product damage and handling time, and support recyclability and cost efficiency across diverse industries.

BRIEF SUMMARY OF THE INVENTION

This summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it to be used as an aid in limiting the scope of the claimed subject matter.

Embodiments of the present invention generally relate to a system, apparatus and method implemented, constructed, and used according to the present invention and designed to improve the functional performance and handling of pallets used in the distribution and delivery of goods. The invention includes a multi-functional plastic pallet with a reduced footprint and optimized geometric configuration to enhance maneuverability, facilitate automated wrapping and scanning procedures, reduce non-productive labor, and improve product stability.

The pallet comprises a durable twin-sheet thermoformed plastic, injection mold plastic, or hybrid composite body with three elongated bottom runners (20) extending longitudinally and a top platform (10) structured to support cases of goods that can be arranged in a pattern where product SKUs are visible from the exterior. Each runner includes beveled entry edges (30) on both longitudinal ends to accommodate a 20-inch-wide pallet jack from either side. Reinforcement posts (25) are integrated between the runners to provide enhanced load-bearing capacity and structural integrity. An optional textured upper surface minimizes slippage of goods during transport.

Additional embodiments of the present invention generally relate to ergonomic and environmental enhancements, including optionally integrated handhold cutouts for easier manipulation by delivery personnel, lightweight construction to reduce strain during manual stacking, and the use of recyclable and recycled materials such as high-molecular-weight polyethylene (HMWPE). The design may include variations in surface texture, depending on the use case, and is particularly well-suited for applications within the beverage industry, including compatibility with Walkie Rider pallet movers and standard wrap machines.

Objects of the invention not understood from the above will be fully understood upon the review of the drawings and the description of the preferred embodiments which follow. Various refinements of the features noted above may exist in relation to various aspects of the present embodiments. Further features may also be incorporated in these various aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to one or more of the illustrated embodiments may be incorporated into any aspect of the present disclosure alone or in any combination. Again, the brief summary presented above is intended only to familiarize the reader with certain aspects and contexts of some embodiments without limitation to the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of embodiments of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying Drawings wherein:

FIG. 1 is a perspective view of a multi-functional pallet, according to one embodiment of the invention.

FIG. 2 is a top view of the multi-functional pallet, according to one embodiment of the invention.

FIG. 3 is a side elevation view of the multi-functional, according to one embodiment of the invention.

FIG. 4 is an end elevation view of the multi-functional, according to one embodiment of the invention.

FIG. 5 is a perspective view of a runner and reinforcement posts, according to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present disclosure may be practiced without such specific details. It is to be understood that both the foregoing general summary description and the following detailed description are illustrative and explanatory, and are not restrictive of the subject matter, as claimed. It is to be further understood that the following disclosure also provides many different embodiments, or examples, for implementing different features of various illustrative embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. For example, a figure may illustrate an exemplary embodiment with multiple features or combinations of features that are not required in one or more other embodiments and thus a figure may disclose one or more embodiments that have fewer features or a different combination of features than the illustrated embodiment. Embodiments may include some but not all the features illustrated in a figure and some embodiments may combine features illustrated in one figure with features illustrated in another figure. Therefore, combinations of features disclosed in the following detailed description may not be necessary to practice the teachings in the broadest sense and are instead merely to describe particularly representative examples. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not itself dictate a relationship between the various embodiments and/or configurations discussed.

In this application, the use of the singular includes the plural, the word “a” or “an” means “at least one”, and the use of “or” means “and/or”, unless specifically stated otherwise. Furthermore, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element” or “component” encompass both elements or components comprising one unit and elements or components that comprise more than one unit unless specifically stated otherwise. In addition, the use of terms such as “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.

In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “inboard,” “outboard,” “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.

As used herein, the terms “connect,” “connection,” “connected,” “in connection with,” and “connecting” may be used to mean in direct connection with or in connection with via one or more elements. Similarly, the terms “couple,” “coupling,” and “coupled” may be used to mean directly coupled or coupled via one or more elements. Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include such elements or features.

The term “substantially,” “approximately,” and “about” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. The extent to which the description may vary will depend on how great a change can be instituted and still have a person of ordinary skill in the art recognized the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding, a numerical value herein that is modified by a word of approximation such as “substantially,” “approximately,” and “about” may vary from the stated value, for example, by 0.1, 0.5, 1, 2, 3, 4, 5, 10, or 15 percent.

The section headings used herein are for organizational purposes and are not to be construed as limiting the subject matter described. If any documents, or portions of documents, are cited in this application, including, but not limited to, patents, patent applications, articles, books, and treatises, such documents are hereby expressly incorporated herein by reference in their entirety for any purpose. In the event that one or more of such incorporated documents and similar materials (if any) defines a term in a manner that contradicts the definition of that term in this application, this application controls.

Referring now to FIG. 1, a perspective view of the pallet 1 is shown. In one embodiment, the pallet 1 includes a body 5 formed as a twin-sheet thermoformed structure that defines an upper deck 10 and a lower deck portion (not shown in this embodiment) that are joined together along their periphery. The body 5 is preferably formed from a plastic material, such as high-density polyethylene (HDPE), polypropylene (PP), or other moldable plastics or hybrid material suitable for durable pallet construction. The twin-sheet thermoforming process creates a continuous peripheral seam that encircles the body 5, closing off internal hollow regions that extend vertically between the upper deck 10 and the lower structural portion of the body 5. These hollow cavities are structurally beneficial, as they reduce overall material usage and weight while retaining sufficient rigidity to bear static and dynamic loads encountered during shipping, stacking, and forklift transport. The interior cavities formed by this process serve to distribute compressive and torsional forces across the pallet 1, with the outer seam and bonded internal web structures providing enhanced structural performance. In other embodiments, the body 5 may be formed by other methods such as rotational molding or injection molding. In particular, injection-molded versions may allow for thicker section walls, greater impact resistance, and increased durability under repetitive loading conditions, making such variants suitable for heavier industrial applications or more abusive environments. As an overall consideration for the present invention, in some implementations when desired, the pallet 1 may be formed using twin-sheet thermoforming, injection molding, or hybrid composites or any combination of plastic-forming methods.

Still referring to FIG. 1, the upper deck 10 forms the primary load-bearing surface of the pallet 1. This component is structured to support a variety of consumer packaged goods, including both full cases and split cases, and is dimensioned to accept a five-tie stacking configuration commonly used in beverage distribution. In the present embodiment, the upper deck 10 is integrally formed as part of the twin-sheet thermoforming process, which enables the top sheet of the body 5 to be contoured with molded-in surface features such as ribs, lips, recesses, or other profile contours for added rigidity and enhanced frictional engagement with the product load. A grain or textured finish may be molded directly into the surface of the upper deck 10, increasing the coefficient of friction between the pallet and the cartons or product containers being carried. This surface texture reduces sliding or shifting of stacked items during transport and allows the pallet to maintain product integrity across various handling stages. The upper deck 10 also defines a series of grid-aligned structural zones where the upper deck reinforcement posts 35 are located, further enhancing the overall compressive strength of the pallet 1.

A plurality of grip apertures 15 are also visible in FIG. 1, located in recessed regions of the upper deck 10. These grip apertures 15 provide ergonomic benefits for warehouse or delivery personnel who may need to manually lift, shift, or realign empty pallets within a stack or during offloading. Each grip aperture 15 is dimensioned and positioned to allow the operator's fingers or gloved hands to securely engage the pallet 1 with minimal strain. These features reduce the need for bending, tipping, or other inefficient motions typically required to manipulate traditional pallets, especially in tight store aisles, coolers, or back-of-house areas. The inclusion of the grip apertures 15 helps improve workplace safety, decrease handling time, and enhance user control during stacking or retrieval operations. However, in other embodiments not shown, the pallet 1 may be formed without the grip apertures 15 without departing from the spirit or scope of the invention.

The underside of the pallet 1 is supported by three longitudinally-extending runners 20, visible in perspective in FIG. 1. These runners 20 are spaced across the width of the body 5 and oriented parallel to the long axis of the pallet 1, enabling directional strength and stability while the pallet is in motion or under load. Each runner 20 forms a continuous, raised rail beneath the lower surface of the pallet 1, allowing it to interface cleanly with standard chain-driven wrap machines, conveyors, and other material handling equipment. The spaced arrangement of the runners 20 also allows the pallet 1 to straddle rails, rollers, or pallet jack forks without catching or tipping. These runners 20 define the bottom load path of the structure and also serve as the mounting base for each corresponding upper deck reinforcement post 35, as described further below.

A series of runner beveled edges 25 are formed at each longitudinal end of the runners 20. These runner beveled edges 25 are sloped upward and inward from the base of each runner 20, providing a ramp-like geometry that facilitates the entry of narrow manual or powered pallet jacks. This geometry is especially critical for compatibility with 20-inch-wide pallet jacks commonly used in store-level operations, where clearance between the wheels and the surrounding pallet structure must be minimized to avoid jamming. The smooth transition of the runner beveled edges 25 allows a pallet jack or Walkie Rider to engage the pallet 1 from either longitudinal end with minimal resistance. The inclusion of the runner beveled edges 25 also helps prevent damage to the pallet or jack wheels caused by abrupt lifting or angled entry attempts, which are common with more rigid traditional pallets.

The outer corners and periphery of the upper deck 10 further include molded upper deck beveled edges 30. These upper deck beveled edges 30 are chamfered or sloped downward slightly along the perimeter of the upper deck 10, particularly near the corners and access zones where stacked products may be loaded or removed. The upper deck beveled edges 30 improve the ability to safely down-stack product from the pallet 1 while also reducing the risk of snagging or impact when pallets are moved within trailers or tight backroom spaces. These edges also assist automated depalletizing systems in aligning the upper perimeter of the pallet 1 with adjacent product loads or lift equipment. Their form may vary slightly depending on the twin-sheet tooling, but the general contour is consistent throughout all various embodiments.

Strategically located throughout the pallet 1 are a plurality of upper deck reinforcement posts 35, which serve a critical structural role in linking the upper deck 10 with each runner 20 below. Each upper deck reinforcement post 35 extends downward from a reinforced area of the upper deck 10 and directly connects to the top surface of a corresponding runner 20. This post-to-runner connection distributes vertical load forces from the deck to the runners and ultimately to the ground or underlying support surface. The number and spacing of the upper deck reinforcement posts 35 are engineered to align with the expected stacking pattern of cases or cartons, ensuring that weight is transferred efficiently along the strongest structural paths of the pallet 1. These posts also help resist deck flexing and preserve flatness over repeated uses, making the pallet 1 suitable for automated wrapping machines and precision alignment operations.

Referring now to FIG. 2, a top view of the pallet 1 is shown. The body 5 presents a rectangular footprint designed to measure approximately 40 inches in length and 27 inches in width. This compact footprint improves maneuverability in constrained environments such as narrow retail aisles, cooler entryways, and congested trailer interiors. The upper deck 10 defines the top surface of the body 5 and serves as the primary load-bearing interface for receiving stacked cases of goods. This upper deck 10 is planar and continuous with a molded-in grain texture across much of its surface, which increases frictional resistance between the pallet 1 and the items supported thereon. This grain-textured finish is especially useful in minimizing product shifting during transport, particularly when loads are shrink-wrapped or secured with minimal restraint. In other embodiments, the upper deck 10 may be formed without a grain-textured finish, and such variations shall not depart from the scope or spirit of the invention.

A series of grip apertures 15 are distributed across the surface of the upper deck 10, visible in FIG. 2 in an aligned rectangular configuration. Each grip aperture 15 extends completely through the body 5 from the upper deck 10 downward, functioning both as an ergonomic handhold and a weight-reducing void. The location of these apertures 15 is designed to provide accessible grasp points for handlers approaching the pallet 1 from various angles. In one embodiment, each grip aperture 15 is approximately 2 inches wide and 6 inches long, although these dimensions may vary to suit different operational or manufacturing constraints. Again, however, in other embodiments not shown, the pallet 1 may be formed without the grip apertures 15 without departing from the spirit or scope of the invention.

The upper deck reinforcement posts 35 are also shown in FIG. 2, arranged in a pattern that aligns with the internal structure of the pallet 1. These posts 35 provide vertical support by linking the upper deck 10 with corresponding positions along the runners 20 located beneath the pallet 1. Their strategic placement ensures that weight from unit loads is transmitted efficiently to the ground, improving both load integrity and resistance to sag. Additionally, the upper deck beveled edges 30 are visible in top view, extending along the corners and periphery of the upper deck 10. These sloped contours reduce edge contact and snagging when the pallet 1 is pushed, pulled, or loaded adjacent to other surfaces or structures.

In some embodiments, the grain texture and upper deck beveled edges 30 are integrally molded into the upper deck 10 during the twin-sheet thermoforming process, ensuring consistency across production batches. The aperture openings for the grip apertures 15 are also formed during this process and may include optional chamfered edge transitions for improved comfort. However, in other embodiments, to reduce manufacturing cost or improve cleaning, the apertures 15 may be left with straight-cut edges. The total number, shape, and positioning of the grip apertures 15 and reinforcement posts 35 may be tailored for specific industry requirements.

Overall, the top view of FIG. 2 reveals how the structural and ergonomic features of the upper deck 10 are configured to meet the functional demands of retail, warehouse, and delivery environments while maintaining compatibility with automated wrapping and scanning systems. The use of strategically placed apertures, molded reinforcement zones, and beveled perimeters illustrates how each design element contributes to the performance and usability of the pallet 1 in the field.

Referring now to FIG. 3, a side elevation view of the pallet 1 is shown. From this orientation, the vertical structural profile of the body 5 can be observed, including the relationship between the upper deck 10, the spaced runners 20, and the upper deck reinforcement posts 35 that structurally connect them. The upper deck 10 is positioned as the topmost surface of the body 5, spanning the full length of the pallet 1 and supported below by the spaced array of upper deck reinforcement posts 35. Each upper deck reinforcement post 35 extends downward from the upper deck 10 and terminates at the top surface of a corresponding runner 20, providing direct vertical load transfer from the load-bearing surface to the support base.

The runners 20 in this view appear as three longitudinal structures positioned along the bottom of the body 5. One central runner 20 is aligned with the longitudinal centerline of the pallet 1, and two additional runners 20 are placed near the lateral margins of the body 5. These runners 20 function as the primary ground-contacting elements of the pallet 1, creating open clearance spaces for forklift and pallet jack entry while maintaining a stable and reinforced base geometry. As seen in this view, each runner 20 interfaces with a series of upper deck reinforcement posts 35, which are symmetrically spaced to align with common case-stacking patterns.

The body 5 is formed as a vertically integrated structure, with hollow regions between the upper deck 10 and the base of the runners 20, as established during the twin-sheet thermoforming process. These hollow regions are not visible in this elevation view but are enclosed within the vertical depth defined by the upper deck 10, upper deck reinforcement posts 35, and runners 20. The overall height of the pallet 1 as viewed in FIG. 3 contributes to its load-bearing capacity and is selected to balance rigidity with weight efficiency.

Referring now to FIG. 4, an end elevation view of the pallet 1 is shown. This view illustrates the transverse configuration of the body 5, including the upper deck 10, the runners 20, and the corresponding structural features that support load distribution and interface with ground-level handling equipment. As shown, three runners 20 extend longitudinally beneath the body 5, with their ends visible in the end view. These runners 20 are spaced to accommodate standard forklift tine spacing and conveyance systems, and provide a stable base for the pallet 1 across its width.

The upper deck 10 extends across the width of the pallet 1 and is bordered along its outer edge by upper deck beveled edges 30. These beveled features taper downward at the perimeter of the upper deck 10 to reduce impact loading and to guide engagement with machinery or adjacent pallets. The upper deck beveled edges 30 improve both safety and handling efficiency during operations where the pallet 1 may come into contact with warehouse structures, stacked loads, or automated equipment.

Each runner 20 terminates at opposing ends with a runner beveled edge 25. The runner beveled edges 25 present a sloped lower edge geometry configured to reduce the likelihood of snagging or resistance during ground-level contact or pallet entry. The beveled profile facilitates easier entry for pallet jacks and forklifts, especially in warehouse environments where speed and reliability of pallet engagement are critical.

Positioned above each runner 20 is an upper deck reinforcement post 35. These upper deck reinforcement posts 35 form a continuous vertical load path between the upper deck 10 and the runners 20, ensuring compressive forces from above are transferred efficiently through the body 5 and into the ground or support surface. The alignment of each upper deck reinforcement post 35 with its underlying runner 20 allows each post-runner pair to operate as a load-bearing column within the structure of the pallet 1. The placement and spacing of the posts 35 are optimized to support typical stacking patterns for unit loads, such as shrink-wrapped cartons or beverage crates.

Referring now to FIG. 5, a perspective view of one of the runners 20 of the pallet 1 is shown. The runner 20 includes a longitudinal base surface extending between opposing ends and provides structural support along the lower face of the pallet 1. This runner 20 is configured to extend along the longitudinal axis of the body 5, and is positioned and dimensioned to engage conveyor belts, racking beams, pallet jack forks, and other handling systems used in typical warehouse and delivery operations.

The underside of the runner 20 includes a plurality of runner beveled edges 25 formed along the ends. Each runner beveled edge 25 defines an upward-sloping surface that facilitates guided entry of equipment forks and reduces impact stress during contact with hard surfaces or edges. The sloped geometry of the runner beveled edges 25 minimizes snagging and helps align the pallet 1 when being inserted into or withdrawn from confined equipment environments such as automated wrappers or trailer floors.

As shown, the runner 20 further includes a series of vertically oriented contact faces at each end that define a reinforced foot structure for stable ground engagement. These contact faces may include molded-in ribs, depressions, or gripping contours to distribute load evenly and resist localized deformation. While only one runner 20 is shown in FIG. 5, the same structure is repeated for each of the three runners 20 positioned beneath the pallet 1, as previously described with respect to FIG. 1.

In some embodiments, the runner 20 may be formed separately from the body 5 and later joined by welding, adhesives, or mechanical interlocks. In other embodiments, the runner 20 is integrally molded with the lower deck portion of the pallet 1 during the twin-sheet thermoforming process or an injection molding process, thereby eliminating assembly steps and improving structural rigidity.

One skilled in the art will recognize that the type of materials disclosed herein from which the present embodiment is constructed are not meant to be limiting and that other suitable materials can be used without departing from the spirit of the invention.

Embodiments of the pallet as provided and disclosed above may be stated in general overall dimensions or in specifics so as to accommodate the specific pallet desired for use. However, other embodiments contemplated by the inventor can have any dimension that also accomplishes the desired function. Although the disclosed embodiments are illustrated as having certain general, absolute, and relative dimensions, those having skill in the art will recognize that the approximate or absolute and relative dimensions illustrated herein can be altered in accordance with varying design considerations. Other embodiments that do not have the same approximate or absolute and relative dimensions can be envisioned without departing from the scope of the invention and claims. Moreover, the disclosed embodiments are not necessarily illustrated to scale.

Without further elaboration, it is believed that one skilled in the art can, using the description herein, utilize the present disclosure to its fullest extent. The foregoing outlines features of several embodiments so that those skilled in the art may better understand the aspects of the disclosure.

Those skilled in the art should appreciate that they may readily use the disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the disclosure. The scope of the invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. The terms “a,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded.