Low Profile, Coated Pallet Assembly

Abstract

A low profile, coated pallet assembly constructed generally of wood, including a generally planar top platform formed of plywood, spacers to provide apertures for a forklift, bottom runners, and is completely encapsulated or coated by a polymeric material. The spacers may include a hollow or foam core to reduce pallet weight but not compromise strength. The bottom runners enhance pallet stability and strength. The polymeric material provides surface friction, resistance to surface damage, and overall integrity to provide a unitary, integral pallet assembly when a substantially uniform coating is applied after pallet components are assembled and affixed.

What is claimed is: 
     
         1 . A low-profile pallet comprising:
 a) a substantially planar top platform formed by a unitary and integral wood surface;   b) a plurality of spacers;   c) a plurality of bottom support runners; and   d) a polymeric coating;   
       wherein the top surface of the pallet is formed of plywood having a thickness of about 0.5 inches to provide a reduced thickness or height profile of the overall pallet; and 
       wherein the polymeric coating is non-pigmented or non-contaminant. 
     
     
         2 . The low-profile pallet of  claim 1 , wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and about 1.5 mm. 
     
     
         3 . The low-profile pallet of  claim 1 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top platform and plurality of bottom runners. 
     
     
         4 . The low-profile pallet of  claim 1 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         5 . The low-profile pallet of  claim 4 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit. 
     
     
         6 . The low-profile pallet of  claim 1 , wherein the substantially planar top platform further includes 8 hand-holds. 
     
     
         7 . The low-profile pallet of  claim 1 , wherein the top surface of the low-profile pallet is formed of plywood having a thickness of about 7/16 inch, wherein deflection of the low-profile pallet from a load up to about 2000 pounds is equivalent to or lesser than a non-coated pallet formed of plywood having a thickness between about ½ inch to about 11/16 inch, wherein the non-coated pallet does not include the polymeric coating. 
     
     
         8 . A low-profile pallet comprising:
 a) a unitary and integral flat top deck surface with a laminate outer layer;   b) a wood cross member positioned below the top deck;   c) a plurality of spacers;   d) a plurality of bottom support runners; and   e) a polymeric coating;   
       wherein the top surface of the pallet is formed of plywood having a thickness of about 0.5 inches to provide a reduced thickness or height profile of the overall pallet; and 
       wherein the polymeric coating is non-pigmented or non-contaminant. 
     
     
         9 . The low-profile pallet of  claim 8 , wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and 1.5 mm. 
     
     
         10 . The low-profile pallet of  claim 8 , wherein the laminate outer layer has a thickness of about 2.7 mm. 
     
     
         11 . The low-profile pallet of  claim 8 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top deck and plurality of bottom runners. 
     
     
         12 . The low-profile pallet of  claim 8 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         13 . The low-profile pallet of  claim 12 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit. 
     
     
         14 . The low-profile pallet of  claim 8 , wherein the top deck further includes 8 hand-holds. 
     
     
         15 . A low-profile pallet comprising:
 a) a unitary and integral flat top deck surface with a laminate outer layer;   b) a plurality of spacers;   c) a plurality of bottom support runners; and   d) a polymeric coating;   
       wherein the top surface of the pallet is formed of plywood having a thickness of about 0.5 inches to provide a reduced thickness or height profile of the overall pallet; and 
       wherein the polymeric coating is non-pigmented or non-contaminant. 
     
     
         16 . The low-profile pallet of  claim 15 , wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and 1.5 mm. 
     
     
         17 . The low-profile pallet of  claim 15 , wherein the laminate outer layer has a thickness of about 2.7 mm. 
     
     
         18 . The low-profile pallet of  claim 15 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top deck and plurality of bottom runners. 
     
     
         19 . The low-profile pallet of  claim 15 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         20 . The low-profile pallet of  claim 19 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit.