Packaging system including a multi-component base structure

Abstract

A pallet base structure including a center deck defining a support surface extending between opposed sides and having at least two lugs extending from each of the opposed sides. A pair of base side members are positioned along respective sides of the center deck. Each base side member has first and second spaced apart base legs and a support member extending between the base legs with at least two corresponding lug receiving slots defined in the support member. The respective lugs are received in the respective lug receiving slots such that the center deck support surface is aligned with an upper surface of each support member to define a planar pallet surface. A packaging system incorporating the pallet base structure is also described.

What is claimed is: 
     
         1 . A pallet base structure comprising:
 a center deck defining a support surface extending laterally between opposed sides, at least two lugs extending from each of the opposed sides; and   a pair of base side members, each base side member having first and second spaced apart base legs and a support member extending between the base legs with at least two corresponding lug receiving slots defined in the support member,   wherein each of the base side members is positioned along a respective side of the center deck and the respective lugs are received in the respective lug receiving slots such that the center deck support surface is aligned with an upper surface of each support member to define a planar pallet surface.   
     
     
         2 . The pallet base structure of  claim 1  wherein each lug has a dovetail configuration and each lug receiving slot has a corresponding dovetail configuration. 
     
     
         3 . The pallet base structure of  claim 1  wherein the at least one of the lugs on one side of the center deck is longitudinally offset from a corresponding lug on the opposite side of the center deck. 
     
     
         4 . The pallet base structure of  claim 1  wherein three lugs extend from each side of the center deck and wherein a forward most lug a first of the sides of the center deck is longitudinally aligned with a forward most lug on the opposite second side of the deck and the remaining lugs on the first side of the center deck are longitudinally offset from the remaining lugs on the second side of the center deck. 
     
     
         5 . The pallet base structure of  claim 1  wherein each lug has a height less than a height of the center deck. 
     
     
         6 . The pallet base structure of  claim 1  wherein each base side member has a longitudinal space defined below the support structure between the base legs. 
     
     
         7 . The pallet base structure of  claim 1  wherein each base side member includes a shock dampener on a lower surface of each base leg. 
     
     
         8 . The pallet base structure of  claim 1  wherein each support member defines at least two spaced apart leg receiving openings. 
     
     
         9 . The pallet base structure of  claim 1  wherein each base side member includes a side wall extending up from the support member. 
     
     
         10 . A pallet base structure comprising:
 a center deck defining a support surface extending between opposed sides;   a pair of base side members, each base side member having first and second spaced apart base legs and a support member extending between the base legs; and   at least two connection members, each connection member configured to releasably connect a respective base side member with the center deck such that the center deck support surface is aligned with an upper surface of each support member to define a planar pallet surface.   
     
     
         11 . The pallet base structure of  claim 10  wherein the connection members are selected from the group comprising clamps, screws, pegs, dowels and lugs. 
     
     
         12 . A packaging system comprising a pallet base structure according to  claim 10 , a cover member configured to be positioned spaced from the pallet base structure, and at least one strap member configured to extend about the pallet base structure and the cover member such that the pallet base structure and the cover member are an interconnected unit. 
     
     
         13 . The packaging system of  claim 12  wherein at least one strap receiving slot is defined across a lower surface of the center deck, along each of the base side members, and across a top surface of the cover member. 
     
     
         14 . The packaging system of  claim 12  wherein the cover member includes a planar portion and a raised center portion defining a concave internal space. 
     
     
         15 . The packaging system of  claim 12  further comprising a wall system configured to be securely positioned between the pallet base structure and the cover. 
     
     
         16 . The packaging system of  claim 15  wherein the pallet base structure and the cover each define wall receiving slots. 
     
     
         17 . A method of packaging a free standing machine comprising a housing supported on a plurality of spaced apart legs such that a lower housing surface is supported spaced from a ground surface upon which the legs are supported, the method comprising:
 positioning a center deck below the lower housing surface between the machine legs, the center deck having a support surface extending between opposed sides;   raising the center deck such that the center deck contacts the lower housing surface and raises the housing until the legs are spaced from the planar surface;   aligning a base side member adjacent each of the center deck opposed sides, each base side member having first and second spaced apart base legs and a support member extending between the base legs;   lowering the center deck until the center deck support surface is aligned with an upper surface of each support member to define a planar pallet surface; and   releasably connecting each base side member to the center deck such that the relative position of the center deck support surface to the upper surface of each support member is maintained and the machine legs are maintained spaced from the ground surface.   
     
     
         18 . The method of  claim 17  wherein each support member defines one or more leg receiving openings and during the lowering step, each of the machine legs is received in a respective leg receiving opening. 
     
     
         19 . The method of  claim 17  further comprising:
 positioning a cover on a top surface of the machine housing; and 
 securing at least one strap about the cover, the center deck and each base side member. 
 
     
     
         20 . The method of  claim 19  further comprising positioning a wall system between the cover and the base side members before securing the at least one strap.