Plastic pallet

Claim 2

A pallet made of a thermoplastic material, the pallet fabricated by joining together a plurality of individually fabricated structural components, each of the structural components being individually thermoformed from an extruded plastic parison having a multilayer structure, the structural components comprising: (a) a deck (2) in the form of a continuous sheet having a longitudinal side (14), a transverse side (15), and top and bottom surfaces, (b) at least one upper runner component (3) having top and bottom surfaces, each said upper runner component (3) comprising a cross member (8) having downward-facing posts (7) and being fastened by its said top surface to said bottom surface of said deck (2), and (c) at least one lower runner component (4), each said lower runner component (4) comprisinq a cross member (8) having upward-facing posts (7), each said upward-facing post fastened to one said downward-facing post of a corresponding said upper runner component (3).

Claim 3

A pallet according to claim 1 wherein at least one said upper runner component (3) fastened to one said lower runner component (4) is positioned along said longitudinal side (14) and along said transverse side (15).

Claim 4

A pallet according to claim 2 wherein one said upper runner component (3) fastened to one said lower runner component (4) is positioned along a said transverse side and has a length substantially equal to said second length.

Claim 5

A pallet according to claim 1 wherein at least one of said top surface of each said upper runner component and the part of said deck to which said upper runner component is fastened is formed with a longitudinal recess, so that a straight open channel (9) is created between said upper runner component and said deck.

Claim 6

A pallet according to claim 4 wherein each said channel (9) is sealed at each end so that a closed hollow space is created.

Claim 7

A pallet according to claim 4 wherein a stiffening section is inserted into one or more of said channels (9).

Claim 8

A pallet according to claim 1 wherein the extruded multilayer structure is fabricated from a thermoplastic selected from polyolefins, PVC, ABS, styrene plastics, PA and PC.

Claim 9

A pallet according to claim 7 wherein said thermoplastic is reinforced with a reinforcing material selected from cut glass fibers and continuous glass fibers, said reinforcing material running in the direction of extrusion.

Claim 10

A pallet according to claim 1 wherein the extruded multilayer structure comprises a foamed plastic layer having a solid skin on one side thereof.

Claim 11

A pallet according to claim 9 wherein said foamed layer and said solid skin are coextruded so that they create an integrated multilayer structure.

Claim 12

A pallet according to claim 9 wherein said foamed layer and said solid skin are made of different materials.

Claim 13

A pallet according to claim 9 wherein said extruded multilayer structure comprises at least one polyolefin material.

Claim 14

A pallet according to claim 12 wherein said foamed layer has a closed cell structure.

Claim 15

A pallet according to claim 1 the extruded multilayer structure comprises at least one foamed plastic layer having a solid skin on both sides thereof.

Claim 16

A pallet according to claim 1 wherein the structural components are joined together by butt welding.

Claim 17

A pallet according to claim 1 wherein the structural components are joined together by the use of a material selected from glue and adhesive.

Claim 18

A pallet according to claim 1 wherein the structural components are joined together mechanically by one or more fastening means selected from snap-together arrangements, clips, bolts made of plastic, and bolts made of metal.

Claim 19

A pallet according to claim 1 wherein at least one of said top and bottom surfaces of said deck are furnished with a plurality of parallel, raised longitudinal sections made of a coextruded friction material.

Claim 20

A pallet according to claim 18 wherein said bottom surface of said upper runner component is furnished with one or more raised longitudinal sections made of a coextruded friction material.

Claim 21

A pallet according to claims 18 or 19 wherein said friction material is a polyolefin material.

Claim 22

A pallet according to claim 20 wherein said polyolefin material is EVA.

Claim 23

A pallet according to claims 17 or 18 wherein said parallel, raised longitudinal sections have a height of about 1 mm and a width of from narrow strips to a continuous facing.

Claim 24

A pallet according to claims 1, 2, or 4 wherein said deck includes one or more structures selected from raised areas and recesses made to fit articles that are to be disposed on the pallet.

Claim 25

A pallet made of a thermoplastic material, the pallet fabricated by joining together a plurality of individually fabricated structural components, each of the structural components being individually thermoformed from an extruded plastic parison having a multilayer structure, the structural components comprising: (a) a deck (2) in the form of a continuous sheet having two longitudinal sides (14) of a first length, two transverse sides (15) of a second length, and top and bottom surfaces, (b) at least two upper runner components (3), each said upper runner component comprising top and bottom surfaces and a cross member (8) having downward-facing posts (7), having a length substantially equal to said second length, and being fastened by said top surface to said bottom surface of said deck (2), each said upper runner component disposed substantially parallel to a said transverse side, and (c) at least two lower runner components (4) comprising a cross member (8) having upward-facing posts (7), each said upward-facing post fastened to one said downward-facing post of a corresponding said upper runner component (3).

Claim 26

A pallet made of a thermoplastic material, the pallet fabricated by joining together a plurality of individually fabricated structural components, each of the structural components being individually thermoformed from an extruded plastic parison having a multilayer structure, the structural components comprising: (a) a deck (2) in the form of a continuous sheet having two longitudinal sides (14) of a first length, two transverse sides (15) of a second length, and top and bottom surfaces, (b) at least two upper runner components (3), each said upper runner component comprising top and bottom surfaces and a cross member (8) having downward-facing posts (7), having a length substantially equal to said second length, and being fastened by said top surface to said bottom surface of said deck (2), each said upper runner component disposed substantially parallel to a said transverse side, and (c) at least two lower runner components (4) comprising a cross member (8) having upward-facing posts (7), each said upward-facing post fastened to one said downward-facing post of a corresponding said upper runner component (3).

Claim 27

A pallet according to claim 24 wherein one said upper runner component (3) fastened to one said lower runner component (4) is positioned along at least each said transverse side (14) of said deck.

Claim 28

A pallet according to claim 25 wherein one said upper runner component (3) fastened to one said lower runner component (4) also is positioned along a said longitudinal side and has a length substantially equal to said first length.

Claim 29

A pallet made of a thermoplastic material, the pallet fabricated by joining together a plurality of individually fabricated structural components, each of the structural components being individually thermoformed from an extruded plastic parison having a multilayer structure, the structural components comprising: (a) a deck (2) in the form of a continuous sheet having two longitudinal sides (14) of a first length, two transverse sides (15) of a second length, and top and bottom surfaces, (b) at least two upper runner components (3), each said upper runner component comprising top and bottom surfaces and a cross member (8) having downward-facing posts (7), one said upper runner component having a length substantially equal to said second length, being fastened by its said top surface to said bottom surface of said deck (2), and disposed substantially parallel to a said transverse side, and the other said upper runner component having a length substantially equal to said first length, being fastened by its said top surface to said bottom surface of said deck (2), and disposed substantially parallel to a said longitudinal side, and (c) at least two lower runner components (4) comprising a cross member (8) having upward-facing posts (7), each said upward-facing post fastened to one said downward-facing post of a corresponding said upper runner component (3).

Claim 30

A pallet made of a thermoplastic material, the pallet fabricated by joining together a plurality of individually fabricated structural components, each of the structural components being individually thermoformed from an extruded plastic parison having a multilayer structure, the structural components comprising: (a) a deck (2) in the form of a continuous sheet having two longitudinal sides (14) of a first length, two transverse sides (15) of a second length, and top and bottom surfaces, (b) at least two upper runner components (3), each said upper runner component comprising top and bottom surfaces and a cross member (8) having downward-facing posts (7), one said upper runner component having a length substantially equal to said second length, being fastened by its said top surface to said bottom surface of said deck (2), and disposed substantially parallel to a said transverse side, and the other said upper runner component having a length substantially equal to said first length, being fastened by its said top surface to said bottom surface of said deck (2), and disposed substantially parallel to a said longitudinal side, and (c) at least two lower runner components (4) comprising a cross member (8) having upward-facing posts (7), each said upward-facing post fastened to one said downward-facing post of a corresponding said upper runner component (3).