Pallet System

Abstract

The present invention includes systems, methods and apparatus for pallets that may be assembled for reliable use, and then easily disassembled into component parts that take up less space during storage and/or shipment. Embodiments of the present invention include an upper platform portion and a lower support portion, in which the upper portion has a plurality of downwardly oriented legs that engage corresponding openings in the lower portion, creating a completed pallet having a vertical space between the upper and lower portions through which the arms of a forklift or other transporting device may be inserted. In some embodiments, the lower portion is made up of a single component part, and in other embodiments the lower portion is made up of a plurality of component parts. The upper and lower portions may be separated after use by applying a separating force, and are separately stackable and therefore take up less space during storage and transport.

1 . A pallet assembly comprising a single upper portion having a generally flat upper surface and a plurality of downwardly extending legs integrally attached thereto, a lower portion comprising no more than three lower support structures, each such structure having at least one opening therein for receiving one of said legs such that an associated opening is provided for each leg, wherein each leg and its associated opening have a complementary tapered shape, wherein insertion of each leg into its associated opening frictionally holds each such leg and opening together, and wherein the width of each of said openings is slightly smaller than the width of each of said legs such that distal ends of said legs do not extend to bottoms of said openings when inserted therein for increasing frictional connectivity under load. 
     
     
         2 . The assembly of  claim 1  wherein at least one side of at least one leg has a rough surface for increasing frictional engagement with the opening associated with such leg. 
     
     
         3 . The assembly of  claim 1  wherein opposite sides of at least one leg have rough surfaces for increasing frictional engagement with the opening associated with such leg. 
     
     
         4 . The assembly of  claim 1  wherein at least one side of at least one opening has a rough surface for increasing frictional engagement with the leg associated with such opening. 
     
     
         5 . The assembly of  claim 1  wherein opposite sides of at least one opening have rough surfaces for increasing frictional engagement with the leg associated with such opening. 
     
     
         6 . The assembly of  claim 1  wherein at least one side of at least one leg has a rough surface, and at least one side of at least one opening also has a rough surface, for increasing frictional engagement at said rough surfaces. 
     
     
         7 . The assembly of  claim 1  wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary slip engagement with a recess in a side of an opening associated with such leg. 
     
     
         8 . The assembly of  claim 2  wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary slip engagement with a recess in a side of an opening associated with such leg. 
     
     
         9 - 10 . (canceled) 
     
     
         11 . The assembly of  claim 1  wherein at least one side of at least one opening has at least one protrusion extending out therefrom for temporary slip engagement with a recess on a leg associated with such opening. 
     
     
         12 . The assembly of  claim 4  wherein at least one side of at least one opening has at least one protrusion extending out therefrom for temporary slip engagement with a recess on a leg associated with such opening. 
     
     
         13 - 15 . (canceled) 
     
     
         16 . The assembly of  claim 1  wherein at least one side of at least one leg has a rough surface for temporary engagement with the opening associated with such leg. 
     
     
         17 . The assembly of  claim 1  wherein opposite sides of at least one leg have rough surfaces for temporary engagement with the opening associated with such leg. 
     
     
         18 . The assembly of  claim 1  wherein at least one side of at least one opening has a rough surface for temporary engagement with the leg associated with such opening. 
     
     
         19 . The assembly of  claim 1  wherein opposite sides of at least one opening have rough surfaces for temporary engagement with the leg associated with such opening. 
     
     
         20 . The assembly of  claim 1  wherein at least one side of at least one leg has a rough surface, and at least one side of at least one opening also has a rough surface, for temporary engagement at said rough surfaces. 
     
     
         21 . The assembly of  claim 1  wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary slip engagement with a recess in a side of an opening associated with such leg. 
     
     
         22 . The assembly of  claim 16  wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary slip engagement with a recess in a side of an opening associated with such leg. 
     
     
         23 - 24 . (canceled) 
     
     
         25 . The assembly of  claim 1  wherein at least one side of at least one opening has at least one protrusion extending out therefrom for temporary slip engagement with a recess on a leg associated with such opening. 
     
     
         26 . The assembly of  claim 18  wherein at least one side of at least one opening has at least one protrusion extending out therefrom for temporary slip engagement with a recess on a leg associated with such opening. 
     
     
         27 - 29 . (canceled) 
     
     
         30 . A method of using pallet systems comprising:
 a. transporting a plurality of upper portions and a plurality of lower portions of pallet systems to a location, each such system comprising an upper portion having a generally flat upper surface and a plurality of downwardly extending legs, a lower portion comprising no more than three lower support structures, each such structure having at least one opening therein for receiving one of said legs such that an associated opening is provided for each leg, wherein each leg and its associated opening have a complementary tapered shape, and wherein the width of each of said openings is slightly smaller than the width of each of said legs such that distal ends of said legs do not extend to bottoms of said openings when inserted therein for increasing frictional connectivity under load, and wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary engagement with a complementary recess on an opening associated with such leg;   b. assembling pallets from said upper and lower portions by inserting the legs of each of said upper portions into a the associated openings in said lower portions to fowl assembled pallets;   c. inserting said at least one protrusion into said complementary recess;   d. transporting goods using said assembled pellets;   e. disassembling said pallets by applying a separating force between the upper and lower portions of each pallet and removing said protrusion from said complementary recess;   f. stacking said separated upper portions together; and   g. separately stacking said separated lower portions together.   
     
     
         31 . (canceled) 
     
     
         32 . A pallet assembly comprising an upper portion having a generally flat upper surface and a plurality of downwardly extending legs, a lower portion comprising at least one lower, support structure, each such structure having at least one opening therein for receiving one of said legs such that an associated opening is provided for each leg, wherein each leg and its associated opening have a complementary tapered shape and wherein insertion of each leg into its associated opening frictionally holds each such leg and opening together, wherein at least one side of at least one leg has at least one rounded knob protruding out therefrom and at least one side of at least one opening has at least one rounded recess for temporarily receiving said at least one knob, and wherein the width of each of said openings is slightly smaller than the width of each of said legs such that distal ends of said legs do not extend to bottoms of said openings when inserted therein for increasing frictional connectivity under load. 
     
     
         33 . A pallet assembly comprising an upper portion having a generally flat upper surface and a plurality of downwardly extending legs, a lower portion comprising at least one lower support structure, each such structure having at least one opening therein for receiving one of said legs such that an associated opening is provided for each leg, wherein each leg and its associated opening have a complementary tapered shape and wherein insertion of each leg into its associated opening frictionally holds each such leg and opening together, wherein at least one side of at least one opening has at least one rounded knob protruding out therefrom and at least one side of at least one leg has at least one rounded recess for temporarily receiving said at least one knob, and wherein the width of each of said openings is slightly smaller than the width of each of said legs such that distal ends of said legs do not extend to bottoms of said openings when inserted therein for increasing frictional connectivity under load. 
     
     
         34 - 36 . (canceled) 
     
     
         37 . A process for transporting goods comprising the steps of:
 a. inserting a plurality of tapered legs of an upper portion of a pallet into a corresponding plurality of complementary tapered openings in no more than three lower pallet support structures wherein the width of each of said openings is slightly smaller than the width of each of said legs such that distal ends of said legs do not extend to bottoms of said openings when inserted therein, thereby forming a pallet;   b. placing a load onto said pallet, forcing said legs into said openings and increasing frictional connectivity therebetween;   c. transporting said loaded pallet from one location to another;   d removing said load from said pallet and decreasing said frictional connectivity; and   e. disassembling said pallet by removing said legs from said openings.   
     
     
         38 . The process of  claim 37  wherein at least one side of at least one leg has at least one protrusion extending out therefrom for temporary engagement with a complementary recess on an opening associated with such leg, and comprising the additional steps of engaging said at least one protrusion with said at least one recess. 
     
     
         39 . The process of  claim 38  comprising the additional step of transporting a formed but unloaded pallet from one location to another, said upper portion and said lower structure being held together during such transport by said at least one protrusion and recess. 
     
     
         40 . The process of  claim 39  comprising the additional step of disassembling said unloaded pallet by applying a separating force between the upper portion and said lower structure of said pallet and removing said protrusion from said recess.