Wooden pallet with end deck boards and butted spacers

Abstract

A pallet includes a base layer and a cargo layer. The cargo layer includes a pair of spaced apart end deck boards, and intermediate deck boards between the pair of spaced apart end deck boards. Spacers are between the end deck boards and the intermediate deck boards. The spacers are positioned so that they butt up against the end deck boards to increase pallet durability. The spacers include block spacers, L-shaped metal brackets and U-shaped metal brackets. Spaced apart supports are coupled between the base and cargo layers and forming a gap therebetween for receiving a lifting member.

That which is claimed: 
     
         1 . A pallet comprising:
 a base layer;   a cargo layer comprising
 a pair of spaced apart outer connector boards, 
 at least one center connector board between said pair of outer connector boards, 
 a pair of spaced apart end deck boards on said pair of outer connector boards and said at least one center connector board, with said end deck boards being orthogonal to said outer connector boards and said at least one center connector board, and 
 a pair of spaced apart intermediate deck boards on said pair of connector boards and said at least one center connector board, with said intermediate deck boards adjacent a respective end deck board and orthogonal to said outer connector boards and said at least one center connector board; 
 a plurality of spacers coupled to said outer connector boards and said at least one center connector board, with an edge of each spacer butted against a respective end deck board; and 
   a plurality of spaced apart supports coupled between said base and cargo layers and forming a gap therebetween for receiving a lifting member, and comprising:
 outer supports configured as a C-shaped bracket having an upper flange contacting one of said outer connector boards and a bottom flange contacting said base layer, and 
 center supports configured as a circular-shaped cylinder having an upper surface contacting said at least one center connector board and a bottom surface contacting said base layer. 
   
     
     
         2 . The pallet according to  claim 1  wherein an opposing edge of each spacer is butted against a respective intermediate deck board. 
     
     
         3 . The pallet according to  claim 2  wherein each spacer is configured as a rectangular-shaped block. 
     
     
         4 . The pallet according to  claim 2  wherein each spacer is configured as a U-shaped bracket. 
     
     
         5 . The pallet according to  claim 1  wherein each spacer is configured as an L-shaped bracket. 
     
     
         6 . The pallet according to  claim 1  wherein a width of each spacer is less than a width of said outer connector boards and a width of said at least one center connector board. 
     
     
         7 . The pallet according to  claim 1  wherein said outer supports comprise metal and said center supports comprise plastic. 
     
     
         8 . The pallet according to  claim 1  wherein said outer and center connector boards comprise wood, and wherein said end and intermediate deck boards comprise wood. 
     
     
         9 . The pallet according to  claim 1  wherein said intermediate deck boards and said end deck boards have a same width. 
     
     
         10 . The pallet according to  claim 1  wherein said cargo layer further comprises at least one additional intermediate deck board between said pair of intermediate deck boards, with said at least one additional intermediate deck board being spaced from said pair of intermediate deck boards. 
     
     
         11 . The pallet according to  claim 1  wherein said base layer comprises a pair of spaced apart bottom end deck boards, and at least one bottom center deck board between said pair of bottom end deck boards, and wherein the bottom flange of each outer support contacts one of said bottom end deck boards or said at least one bottom center deck board. 
     
     
         12 . The pallet according to  claim 11  wherein said bottom end deck boards and said at least one bottom center deck board are aligned with said end deck boards and said intermediate deck boards in said cargo layer. 
     
     
         13 . The pallet according to  claim 1  wherein each circular-shaped cylinder comprises a center hub with an opening extending therethrough, an outer wall, and a plurality of ribs extending between said center hub and said outer wall. 
     
     
         14 . The pallet according to  claim 13  wherein said base and cargo layers include fastener openings aligned the openings in the center hubs in said center supports, and further comprising a plurality of fasteners for coupling said base and cargo layers to said center supports. 
     
     
         15 . The pallet according to  claim 13  wherein said plurality of ribs are recessed from opposing ends of the center hub and the outer wall. 
     
     
         16 . The pallet according to  claim 1  wherein the upper flange in each outer support includes a single fastener opening extending therethrough, and the bottom flange in each outer support includes a pair of fastener openings extending therethrough; and
 said base and cargo layers include fastener openings aligned the openings in said outer supports, and further comprising a plurality of fasteners for securing said base and cargo layers to said outer supports. 
 
     
     
         17 . A method for making a pallet comprising:
 providing a base layer;   providing a cargo layer comprising
 a pair of spaced apart outer connector boards, 
 at least one center connector board between said pair of outer connector boards, 
 a pair of spaced apart end deck boards on said pair of outer connector boards and said at least one center connector board, with said end deck boards being orthogonal to said outer connector boards and said at least one center connector board, and 
 a pair of spaced apart intermediate deck boards on said pair of connector boards and said at least one center connector board, with said intermediate deck boards adjacent a respective end deck board and orthogonal to said outer connector boards and said at least one center connector board; 
 a plurality of spacers coupled to said outer connector boards and said at least one center connector board, with an edge of each spacer butted against a respective end deck board; and 
   coupling a plurality of spaced apart supports between said base and cargo layers and forming a gap therebetween for receiving a lifting member, with the supports comprising:
 outer supports configured as a C-shaped bracket having an upper flange contacting one of said outer connector boards and a bottom flange contacting said base layer, and 
 center supports configured as a circular-shaped cylinder having an upper surface contacting said at least one center connector board and a bottom surface contacting said base layer. 
   
     
     
         18 . The method according to  claim 17  wherein an opposing edge of each spacer is butted against a respective intermediate deck board. 
     
     
         19 . The method according to  claim 18  wherein each spacer is configured as a rectangular-shaped block. 
     
     
         20 . The method according to  claim 18  wherein each spacer is configured as a U-shaped bracket. 
     
     
         21 . The method according to  claim 17  wherein each spacer is configured as an L-shaped bracket. 
     
     
         22 . The method according to  claim 17  wherein a width of each spacer is less than a width of said outer connector boards and a width of said at least one center connector board. 
     
     
         23 . The method according to  claim 17  wherein each circular-shaped cylinder comprises a center hub with an opening extending therethrough, an outer wall, and a plurality of ribs extending between the center hub and the outer wall. 
     
     
         24 . The method according to claim  25  wherein the plurality of ribs are recessed from opposing ends of the center hub and the outer wall.