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A thermoformed twin sheet pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced relation and defining a plurality of forklift passages there

A thermoformed twin sheet pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced relation and defining a plurality of forklift passages therebetween. The leg structures are formed of spaced downstanding leg portions of the upper sheet fused in vertically overlapping relation to spaced upstanding leg portions of the lower sheet, and main body planar portions of the upper sheet between the spaced downstanding leg portions coact with main body planar portions of the lower sheet between the spaced upstanding leg portions to define the forklift passages. The lower sheet further includes an upstanding flange portion extending around the perimeter of the lower sheet and fused to the perimeter of the upper sheet and openings are provided in the flange portion, in alignment with the forklift passages, to provide forklift access to the forklift passages. A flap is provided in each opening which is yieldable to allow entry of a forklift into the opening for access to the respective forklift passage. The downstanding leg portions of the upper sheet comprise clusters of hollow protrusions opening in the upper face of the upper sheet and the upstanding leg portions of the lower sheet comprise clusters of hollow protrusions opening in the lower face of the lower sheet and including sidewalls fused to sidewalls of the downstanding protrusions of the upper sheet.

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The invention claimed is: 1. A thermoformed twin sheet plastic pallet consisting of an upper plastic sheet and a lower plastic sheet, the upper and lower sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced rel

The invention claimed is: 1. A thermoformed twin sheet plastic pallet consisting of an upper plastic sheet and a lower plastic sheet, the upper and lower sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced relation and defining a plurality of forklift passages therebetween, characterized in that: the leg structures comprise spaced clusters of downstanding protrusions in the upper sheet fused in vertically overlapping relation to spaced clusters of upstanding protrusions in the lower sheet; the downstanding protrusions in each cluster of downstanding protrusions are intermeshed with and fused to the upstanding protrusions in a cluster of upstanding protrusions; and main body flat planar portions of the upper sheet, located between the spaced clusters of downstanding protrusions and devoid of protrusions, coact with main body flat planar portions of the lower sheet, located between the spaced clusters of upstanding protrusions and devoid of protrusions, to define upper and lower boundaries of the forklift passages with the vertical boundaries of the forklift passages defined by the leg structures. 2. A pallet according to claim 1 wherein: the clusters of downstanding protrusions in the upper sheet comprise upper, hollow protrusions opening in the upper face of the upper sheet; and the clusters of upstanding protrusions in the lower sheet comprise lower, hollow protrusions opening in the lower face of the lower sheet and including side walls fused to side walls of the upper protrusions. 3. A pallet according to claim 2, wherein a plurality of upstanding protrusions are fused to a least certain of the downstanding protrusions. 4. A pallet according to claim 3, wherein at least three upstanding protrusions are fused to at least one of the downstanding protrusions. 5. A pallet according to claim 2, wherein each protrusion has a frusto conical vertical cross-section. 6. A pallet according to claim 1, wherein: the upper and lower sheets have a generally rectangular configuration; and leg structures are defined at the corners of the pallet and at intermediate locations along each side of the pallet, whereby to define a pair of forklift passages extending lengthwise of the pallet and a pair of forklift passages extending crosswise of the pallet. 7. A thermoformed twin sheet plastic pallet consisting of an upper plastic sheet and a lower plastic sheet, the upper and lower sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure and defining a plurality of forklift passages therebetween, characterized in that: the leg structures comprise spaced clusters of downstanding protrusions in the upper sheet fused in vertically overlapping relation to spaced clusters of downstanding protrusions in the lower sheet; the downstanding protrusions in each cluster of downstanding protrusions are intermeshed with and fused to the upstanding protrusions in a cluster of upstanding protrusions; main body planar portions of the upper sheet between the leg structures coact with main body planar portions of the lower sheet between the leg structures to define upper and lower boundaries of the forklift passages; the clusters of upstanding and downstanding protrusions coact to define vertical side boundaries for the forklift passages; and the lower sheet further includes an upstanding flange portion extending around the perimeter of the lower sheet and extending upwardly outside of the leg structures for fusion to the perimeter of the upper sheet. 8. A thermoformed twin sheet plastic pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure and defining a plurality of forklift passages therebetween, characterized in that: the upper sheet includes spaced clusters of protrusions extending downwardly from the upper sheet and planar main body portions between the clusters; the lower sheet includes spaced clusters of hollow protrusions extending upwardly form the lower sheet and planar main body portions between the clusters; the protrusions in each cluster of upstanding protrusions are intermeshed with and fused to the protrusions in a cluster of downstanding protrusions; the main body portions of the upper sheet define the upper boundary of the forklift passages; the main body portions of the lower sheet define the lower boundaries of the forklift passages; the leg structures define vertical boundaries of the forklift passages; the lower sheet further includes an upstanding flange portion extending around the perimeter of the lower sheet and extending upwardly outside of the leg structures for fusion to the perimeter of the upper sheet; and the forklift passages include a pair of parallel forklift passages each extending across the pallet from a location proximate a section of the flange portion to a location proximate an opposite section of the flange portion; and openings are provided in the flange portion sections, in alignment with the forklift passages, to provide forklift access to the forklift passages. 9. A pallet according to claim 8, wherein a flap is provided in each opening which is yieldable to allow entry of a forklift into the opening for access to the respective forklift passage. 10. A twin sheet plastic pallet including a plastic upper sheet and a plastic lower sheet selectively fused together to form the pallet, characterized in that: one of the sheets has a plurality of spaced clusters of protuberances extending outwardly from the general plane of the sheet; the sheets are fused together with the clusters of protuberances positioned between the sheets to define a space between the sheets and define a plurality of leg structures for the pallet constituted by the clusters of protuberances; the clusters are spaced apart sufficiently to define parallel passages therebetween each having a width sufficient to accommodate the width of a fork of a forklift truck; the protuberances have a vertical dimension such that the space between the sheets is sufficient to accommodate the thickness of the fork; and the spacing between and the pattern of the clusters of protuberances is such that the spacing between the parallel passages corresponds to the spacing between the forks of a forklift truck. 11. A twin sheet pallet according to claim 10 wherein: the other sheet also has a plurality of spaced clusters of protuberances extending outwardly from the general plane of the sheet and corresponding in number and spacing to the clusters of protuberances on the one sheet; and with the sheets fused together the protrusions of the clusters of protrusions of the one sheet intermesh with the protrusions of the clusters of the protrusions of the other sheet. 12. A thermoformed twin sheet plastic pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced relation and defining a plurality of forklift passages therebetween, characterized in that: the leg structures are formed of spaced downstanding leg portions of the upper sheet fused in vertically overlapping relation to spaced upstanding leg portions of the lower sheet; and main body planar portions of the upper sheet between the spaced downstanding leg portions coact with main body planar portions of the lower sheet between the spaced upstanding leg portions to define the forklift passages; the lower sheet further includes an upstanding flange portion extending around the perimeter of the lower sheet and fused to the perimeter of the upper sheet; the forklift passages include a pair of parallel forklift passages extending across the pallet from a location proximate a section of the flange portion to a location proximate an opposite section of the flange portion; and openings are provided in the flange portion sections in alignment with the forklift passages to provide forklift access to the forklift passages. 13. A pallet according to claim 12 wherein a flap is provided in each opening which is yieldable to allow entry of a forklift into the opening for access to the respective forklift passage. 14. A thermoformed twin sheet plastic pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure in spaced relation and defining a plurality of forklift passages therebetween, characterized in that: the leg structures are formed of spaced downstanding leg portions of the upper sheet fused in vertically overlapping relation to spaced upstanding leg portions of the lower sheet; main body planar portions of the upper sheet between the spaced downstanding leg portions coact with main body planar portions of the lower sheet between the spaced upstanding leg portions to define the forklift passages; the downstanding leg portions of the upper sheet comprise upper, hollow protrusions opening in the upper face of the upper sheets; the upstanding leg portions of the lower sheet comprise lower, hollow protrusions opening in the lower face of the lower sheet and including side walls fused to the side walls of the upper protrusions; a plurality of upstanding protrusions are fused to at least certain of the downstanding protrusions; at least three upstanding protrusions are fused to at least one of the downstanding protrusions; the protrusions have a circular transverse cross-section; and lines of fusion are formed between the three upstanding protrusions and the one downstanding protrusion and the lines of fusion are spaced circumferentially about the one downstanding protrusion. 15. A pallet according to claim 14, wherein the lines of fusion are spaced equally about the circumference of the one downstanding protrusion. 16. A thermoformed twin sheet plastic pallet comprising an upper plastic sheet and a lower plastic sheet, the sheets being fused together to form a platform structure and a plurality of leg structures downstanding from the platform structure and defining a plurality of forklift passages therebetween, characterized in that: main body planar portions of the upper sheet between the leg structures coact with main body planar portions of the lower sheet between the leg structures to define upper and lower boundaries of the forklift passages; the leg structures coact to define vertical side boundaries for the forklift passages; the lower sheet further includes an upstanding flange portion extending around the perimeter of the lower sheet and extending upwardly outside of the leg structures for fusion to the perimeter of the upper sheet; the forklift passages include a pair of parallel forklift passages extending across the pallet from a location proximate a section of the flange portion to a location proximate an opposite section of the flange portion; and openings are provided in the flange portion sections, in alignment with the forklift passages, to provide forklift access to the forklift passages. 17. A pallet according to claim 16, wherein a flap is provided in each opening which is yieldable to allow entry of a forklift into the opening for access to the respective forklift passage. 18. A pallet according to claim 17, wherein each leg structure is constituted by a plurality of hollow protrusions upstanding from the lower sheet fused to a plurality of hollow protrusions downstanding from the upper sheet. 19. A pallet according to claim 18, wherein: each protrusion includes a sidewall; and the upstanding and downstanding protrusions are fused together along interfacing sidewalls. 20. A pallet according to claim 19, wherein at least one downstanding protrusion is fused to at least three upstanding protrusions.