Abstract: A method is provided for forming a pallet including thermoforming a pair of plastic sheets and then fusing the two sheets together to form the pallet. One of the two sheets is thermoformed to provide a series of pin assemblies with each pin assembly including a plurality of hollow pin portions extending outwardly. The second sheet is thermoformed to provide a series of leg portions that define a corresponding series of grooves in the sheet, each groove corresponding to a respective pin assembly of the first sheet. The first sheet is assembled with the second sheet such that each pin assembly of the first sheet rests nestingly within the respective groove of the second sheet and then the material of the pin assemblies are fused to the material of the respective grooves. Web portions of the first sheet interconnect adjacent pin portions and are formed as folds extending outwardly in the same direction as the pin portions, but to a lesser extent.

Abstract: A method of forming a metal and plastic composite structure including providing an elongated metallic element; providing first and second plastic sheets; heat forming the first and second plastic sheets to form first and second preformed plastic parts; and, following the individual heat forming of the parts and with the parts in a hot flowable state, assembling the plastic parts and the metallic element by fusing portions of the parts together with the metallic element positioned therebetween to form a composite assembly comprising a twin sheet plastic structure with the metallic element sandwiched therebetween. Also disclosed are composite structures, including a motor vehicle head rest and a seat back for a motor vehicle seat assembly, constructed in accordance with the invention methodology.

Abstract: A bulk liquid container including a pallet defining an annular outer peripheral portion defining an upwardly facing annular seat and a central platform portion within the outer peripheral portion; an annular cage including an annular sidewall structure and an annular lower edge positioned on the annular seat; and a bulk liquid bottle positioned in the sleeve with its sidewall structure juxtaposed to the sleeve sidewall structure and its bottom positioned on the platform portion. The pallet defines an upstanding rim extending around the annular seat and a plurality of circumferentially spaced channels opening inwardly of the annular seat and above the seat. A plurality of straps extend through openings in the rim and through an opening in the lower annular portion of the cage for passage into a respective channel.

Abstract: A container especially suitable for bulk materials and including a cardboard tubular sleeve having its lower edge portion positioned in upwardly opening groove means on a plastic pallet. The tubular sleeve is a sleeve assembly comprising inner and outer tubular sleeves respectively formed of first and second corrugated cardboard structures with the inner sleeve positioned telescopically within the outer sleeve and with the outer annular surface of the inner sleeve secured to the inner annular surface of the outer sleeve to form a composite sleeve assembly having a thickness approximating the width of the groove means on the pallet. An auxiliary cardboard sheet is secured to the outboard surface of the outer tubular sleeve and an auxiliary cardboard sheet is secured to the inboard surface of the inner cardboard sleeve.

Abstract: A plastic pallet in which a base structure is positioned beneath the plastic main body of the pallet to discourage warpage and failure of the pallet especially in racked, loaded storage situations. The plastic structure of the pallet includes a planar platform section defining an upwardly facing load receiving surface and a plurality of legs extending downwardly from the platform section to define tunnels therebetween for receipt of the forks of a forklift truck. The base structure includes a lower plastic sheet, an upper plastic sheet, and a plurality of tubular metallic beams positioned in hollows defined between the upper and lower plastic sheets.

Abstract: An improved laminated structural material; an improved method of forming a relatively rigid structural article such as a pallet; and an improved structural article using the invention laminated structural material.

Abstract: A container especially suitable for bulk materials and including a cardboard tubular sleeve having its lower edge portion positioned in upwardly opening groove means on a plastic pallet. The tubular sleeve is a sleeve assembly comprising inner and outer tubular sleeves respectively formed of first and second corrugated cardboard structures with the inner sleeve positioned telescopically within the outer sleeve and with the outer annular surface of the inner sleeve secured to the inner annular surface of the outer sleeve to form a composite sleeve assembly having a thickness approximately the width of the groove means on the pallet. An auxiliary cardboard sheet is secured to the outboard surface of the outer tubular sleeve and an auxiliary cardboard sheet is secured to the inboard surface of the inner cardboard sleeve.

Abstract: A plastic pallet in which a plurality of beam assemblies are positioned beneath the plastic main body of the pallet to discourage warpage and failure of the pallet, especially in racked, loaded storage situations. The plastic structure of the pallet includes a planar platform section defining an upwardly facing load receiving surface and a plurality of legs extending downwardly from the platform section to define tunnels therebetween for receipt of the forks of a forklift truck. The beam structures extend in parallel fashion beneath the plastic structure. Each beam structure includes a central upstanding spine portion received in downwardly opening grooves defined in the bottoms of aligned legs, and a base portion which extends beneath the bottoms of the legs to provide a base on which each pallet may rest.

Abstract: A method of forming a twin sheet plastic pallet formed of an upper and a lower sheet and utilizing an upper male mold having downwardly extending leg protrusions and a lower female mold having complementary upwardly opening leg cavities. The method includes introducing the lower sheet between the spaced upper and lower molds, vacuum forming the lower sheet to the molding surfaces of the upper mold, vacuum forming the lower sheet to the molding surfaces of the lower mold, introducing the upper sheet between the spaced molds, vacuum forming the upper sheet to the molding surfaces of the upper mold, and bringing the upper and lower molds together with their leg portions in nested relation to fuse the upper and lower sheets together along their peripheries and at the interfaces their nested leg portions to form the final pallet.

Abstract: A plastic pallet in which an insert assembly is positioned within the hollow of the plastic pallet to discourage warpage and failure especially in racked, storage situations. The insert assembly comprises a pair of beams arranged in an X-configuration, tower members secured at their upper ends to respective ends of the beams and positioned respectively in the four corners of the pallet, and tensioning straps extending between the tower members around the perimeter of the pallet proximate the upper surface of the bottom wall of the pallet. The X-configured beams are positioned in the space between the spaced upper and lower sheets of the platform structure of the pallet and are maintained in a convexly bowed configuration by the tensioning straps so as to resist downward bowing of the platform structure, even when the pallet is racked for extended periods of time in a loaded condition.

Abstract: A container especially suitable for bulk materials and inlcuding a cardboard tubular sleeve having its lower edge portion positioned in upwardly opening groove means on a plastic pallet. The tubular sleeve is a sleeve assembly comprising inner and outer tubular sleeves respectively formed of first and second corrugated cardboard structures with the inner sleeve positioned telescopically within the outer sleeve and with the outer annular surface of the inner sleeve secured to the inner annular surface of the outer sleeve to form a composite sleeve assembly having a thickness approximating the width of the groove means on the pallet. An auxiliary cardboard sheet is secured to the outboard surface of the outer tubular sleeve and an auxiliary cardboard sheet is secured to the inboard surface of the inner cardboard sleeve.

Abstract: A method and apparatus for handling sheet metal stampings utilizing a tack including a base structure defining a floor surface, upstanding end structures, and forklift openings to facilitate transport of the rack. A plurality of leaves are positioned in spaced relation along the floor surface with each leaf including a hinge along its lower edge defining a hinge axis extending normal to the longitudinal axis of the rack. The leaf nearest one of the end structures is spaced from that end structure to allow that leaf to assume a pivoted position on one side of a reference plane in which the upper end of the leaf is supported by the one end structure and the leaf nearest the other end structure is spaced from that end structure to allow that leaf to assume a pivoted position on the other side of its reference plane in which the leaf is supported by the other end structure.

Abstract: A roof ridge vent of a unitary plastic construction formed in a twin sheet process by separately thermoforming upper and lower sheets and then bringing the sheets together to selectively fuse them at their interfaces. The completed roof vent includes a central longitudinal hinge portion adapted to overlie the ridge of the roof and left and right longitudinal vent portions joined integrally to the central hinge portion along their respective inboard edges and positioned at either side of the hinge portion. The vent portions are configured to define a plurality of parallel transverse passages in each vent portion extending from the outboard edge of the vent portion to a location proximate the hinge portion with each passage closed at its lower face in the outboard section of the passage and open at its lower face in the inboard section of the passage for communication with an opening provided along the ridge of the roof to provide ventilation for the space beneath the roof.

Abstract: A plastic reinforcing structure for use with a container of the type including a corrugated sleeve adapted to be removably attached to a plastic pallet or base member by the use of sliding latch members coacting with slots in the lower peripheral portion of the sleeve. The reinforcing structure is formed as a single piece of plastic material and includes an inner planar portion, an outer planar portion, a central wall portion, and inner and outer tubular portions carrying lips on their leading edges. In use, the central wall of the reinforcing structure is positioned under and along the lower edge of the sleeve beneath a slot in the sleeve and the inner and outer planar portions are swung upwardly about live hinges provided between the bottom wall and the inner and outer planar portions.

Abstract: A plastic pallet of twin sheet construction formed in a vacuum thermal forming process. The upper sheet includes a series of downwardly extending hollow upwardly opening bosses arranged in staggered rows and the lower sheet includes a series of upwardly extending hollow downwardly opening bosses generally corresponding in size, number, shape and distribution pattern to the downwardly extending bosses on the upper sheet. The lower walls of the downwardly extending bosses are fused to the upper walls of the upwardly extending bosses in the thermal forming process so as to form a series of vertical columns extending between the upper and lower sheets and maintaining the sheets in fixed spaced relation. The pallet further includes a plurality of legs spaced circumferentially about the periphery of the pallet and depending downardly from the pallet.

Abstract: A reusable plastic base serves as a pallet which may be lifted by the forks of a fork-lift truck. A sleeve is removably attached to the base and forms the sidewalls of the container. In the preferred embodiment, the sleeve is made of corrugated material having slots formed along its lower edge. The slots are adapted to coact with latch members slidably mounted in the base to releasably secure the pallet to the sleeve. The base is preferably designed with a peripheral groove lying substantially at floor level to receive the edge of the sleeve. Compressive loads applied to the container are transferred to the sleeve directly to the floor, thereby minimizing deformation of peripheral portions of the base.

Abstract: A reusable plastic base serves as a pallet which may be lifted by the forks of a forklift truck. A sleeve is removably attached to the base and forms the sidewalls of the container. In the preferred embodiment, the sleeve is made of corrugated material having slots formed along its lower edge. The slots are adapted to coact with latch members slidably mounted in the base to releasably secure the pallet to the sleeve. The base is preferably designed with a peripheral groove lying substantially at floor level to receive the edge of the sleeve. Compressive loads applied to the container are transferred to the sleeve directly to the floor, thereby minimizing deformation of peripheral portions of the base.

Abstract: A twin sheet pallet comprising a lower sheet having a substantially continuous downwardly opening U-shaped groove extending around its periphery for stacking receipt of the upper edge portion of the sleeve of a lower container, and an upper sheet having a substantially continuous upwardly opening U-shaped groove extending around its periphery for stacking receipt of an upper container sleeve which at least portions of the peripheral undersurface of the upper sheet underlying the upwardly opening groove bonded to at least portions of the peripheral upper surface of the lower sheet overlying the downwardly opening groove to form a unitary twin sheet pallet. The upwardly opening groove in the upper sheet is stepped upwardly at circumferentially spaced locations about that groove and an opening is provided in the outer wall of the upper sheet in alignment with each upward step to allow passage of the forks of a forklift truck.

Abstract: A twin sheet pallet constructed by forming a lower polygonal plastic sheet to define an upwardly opening U-shaped groove around its periphery; forming an upper polygonal plastic sheet to define a plurality of circumferentially spaced upwardly opening U-shaped protrusions extending downwardly from the general plane of the sheet and sized to nest in the groove of the upper sheet; positioning the upper sheet over the lower sheet with the protrusions on the upper sheet nested at circumferentially spaced locations in the groove of the lower sheet; fusing the upper and lower sheets together to form double thickness U-shaped wall structures at the interfaces of the protrusions and the groove; and cutting aligned horizontally extending slots in the opposite sides of the U-shaped structures to allow entry of the forks of a forklift truck.

Abstract: A pallet system including two embodiments of a pallet having a deck including four sides and providing a load-supporting surface. A plurality of spaced hollow legs project from the opposite side of the deck and a plurality of hollow reinforcing ribs project from the opposite surface to define channels in the load-supporting surface. A hollow ridge projects from the opposite surface and extends along the sides at the periphery of the deck to define a groove in the load-supporting surface for receiving the bottom edge of a wall. There is at least one transverse rib projecting from the opposite surface and extending between opposite sides of the deck to define a transverse groove in the load-supporting surface for receiving the bottom edge of a transverse wall whereby walls may extend upwardly from the deck to divide and separate the load-supporting surface into discrete areas.