Modular pallets

Abstract

A modular pallet formed from a plurality of frame members and a plurality of deck members. The deck members extend between the frame members to define an upper deck surface and optionally a lower deck surface of the pallet. A plurality of spaced-apart channels are formed in at least an upper surface of the frame members to receive the deck members. In some embodiments the pallet may be configured as a stringer pallet and in other embodiments the pallet may be configured as a block pallet. In some embodiments the frame members are unitary stringers. In other embodiments the frame members are modular structures each comprising a block pallet subassembly and a deck support panel. The number, size, orientation and spacing of the channels formed in the frame members and the corresponding arrangement of the deck members may vary in different embodiments of the pallet. Once assembled, the frame members and deck members may be integrally connected, such as by heat welding. In some embodiments the pallet is formed from readily recyclable plastic.

What is claimed is: 
     
         1 . A modular pallet comprising:
 (a) a plurality of elongated frame members arranged in spaced-apart relation, wherein each of said frame members comprises an upper surface and a lower surface and wherein at least said upper surface has a plurality of spaced-apart channels formed therein; and   (b) a plurality of elongated deck members positionable in said channels for coupling said frame members together, wherein each of said channels receives one of said deck members when said pallet is assembled,   wherein said pallet has a deck surface area for supporting a load defined by the multiple of a length of one of said frame members and a length of one of said deck members, wherein said deck members are spaced within said channels such that upper surfaces of said frame members and said deck members comprise less than about 50% of said deck surface area.   
     
     
         2 . The pallet as defined in  claim 1 , wherein each of said deck members being substantially square in cross-section and comprising first, second, third and fourth outer surfaces, wherein each of said channels comprises a planar inner surface substantially free from slots or protuberances and wherein each of said deck members is snugly positionable within a corresponding one of said channels in an orientation wherein any one of said outer surfaces of said deck members contacts said inner surface of said channel. 
     
     
         3 . A modular pallet comprising:
 (a) a plurality of elongated frame members arranged in spaced-apart relation, wherein each of said frame members comprises an upper surface and a lower surface and wherein each of said upper surface and said lower surface has a plurality of spaced-apart channels formed therein; and   (b) a plurality of elongated deck members positionable in said channels for coupling said frame members together, wherein each of said deck members has a first planar surface and a second planar surface opposite said first planar surface, wherein each of said deck members is positionable in said channels formed in said frame members in either a first configuration wherein said first surface extends outwardly co-planar with said upper surface of said frame members thereby forming part of a planar upper deck surface of said pallet or in a second configuration wherein said second surface extends outwardly co-planar with said upper surface of said frame members thereby forming part of a planar upper deck surface of said pallet; and   wherein said pallet has a deck surface area for supporting a load defined by the multiple of a length of one of said frame members and length of one of said deck members, wherein said deck members are spaced within said channels such that upper surfaces of said frame members and said deck members comprise less than about 50% of said deck surface area.   
     
     
         4 . A kit for forming a pallet comprising:
 (a) a plurality of elongated frame members positionable in spaced-apart relation, each comprising an upper surface and a lower surface, wherein each of said upper surface and said lower surface has a plurality of spaced-apart channels formed therein; and   (b) a plurality of elongated deck members positionable within said channels for coupling said frame members together without mechanical connectors, wherein each of said deck members has a uniform width, is rectangular in cross-section and comprises a first planar surface and a second planar surface opposite said first planar surface.   
     
     
         5 . The kit as defined in  claim 4 , wherein each of said frame members has a longitudinal axis extending along a length thereof and wherein each of said channels extends transversely substantially perpendicular to said longitudinal axis. 
     
     
         6 . The kit as defined in  claim 4 , wherein said frame members and said deck members are formed from plastic. 
     
     
         7 . The kit as defined in  claim 4 , wherein each of said frame members is a stringer of unitary construction. 
     
     
         8 . A method of forming a pallet comprising:
 (a) providing a kit as defined in  claim 4 ;   (b) arranging said frame members in spaced-apart relation such that said channels in corresponding ones of said frame members are aligned;   (c) inserting said deck members within said channels such that said deck members extend to connect said frame members together; and   (d) integrally connecting said deck members to said frame members.   
     
     
         9 . The method as defined in  claim 8 , wherein said frame members and said deck members are formed from plastic and wherein said connecting comprises heat welding said deck members to said frame members. 
     
     
         10 . A block pallet subassembly for a pallet comprising:
 (a) a plurality of spaced-apart blocks, wherein each of said blocks has a plurality of slots formed therein; and   (b) a plurality of elongated stringer members positionable in said slots for coupling said blocks together.   
     
     
         11 . The block pallet subassembly as defined in  claim 10 , wherein each of said blocks is generally parallelepiped in shape and comprises three pairs of opposed faces, wherein said slots are formed in at least one of said faces. 
     
     
         12 . The block pallet subassembly as defined in  claim 11 , wherein said slots are formed in at least one pair of said opposed faces. 
     
     
         13 . The block pallet subassembly as defined in  claim 10 , wherein said blocks and said stringer members are formed of plastic. 
     
     
         14 . A pallet comprising a plurality of block pallet subassemblies each as defined in  claim 10  and a deck positionable on said subassemblies. 
     
     
         15 . The pallet as defined in  claim 14 , wherein said deck comprises a plurality of elongated, spaced-apart deck members. 
     
     
         16 . The pallet as defined in  claim 15  wherein said deck comprises a plurality of deck support panels each positionable on one of said subassemblies and each comprising a plurality of channels for receiving said deck members. 
     
     
         17 . The pallet as defined in  claim 16 , wherein said deck members and said deck support panels are formed of plastic. 
     
     
         18 . A modular pallet comprising:
 (a) a plurality of elongated frame members arranged in spaced-apart relation, wherein each of said frame members comprises an upper surface, a lower surface, and a plurality of spaced-apart channels formed in at least said upper surface; and   (b) a plurality of elongated deck members positionable in said channels for extending between said frame members to form an upper deck of said pallet.   
     
     
         19 . The pallet as defined in  claim 18 , wherein said upper deck has a deck surface area for receiving a load and wherein said deck members are spaced within said channels such that said deck members comprise less than about 60% of said deck surface area. 
     
     
         20 . The pallet as defined in  claim 19 , wherein said deck members comprise less than about 50% of said deck surface area. 
     
     
         21 . The pallet as defined in  claim 20 , wherein said deck members comprise less than about 35% of said deck surface area. 
     
     
         22 . The pallet as defined in  claim 19 , wherein the spacing between said channels formed in each of said frame members is non-uniform. 
     
     
         23 . A modular pallet comprising:
 (a) a plurality of elongated frame members arranged in spaced-apart relation, wherein each of said frame members comprises an upper surface and a lower surface and wherein at least said upper surface has a plurality of spaced-apart channels formed therein; and   (b) a plurality of elongated deck members positionable in said channels for coupling said frame members together.   
     
     
         24 . A modular pallet comprising:
 (a) a plurality of elongated frame members arranged in spaced-apart relation, wherein each of said frame members comprises an upper surface and a lower surface and wherein at least the upper surface has a plurality of spaced-apart channels formed therein; and   (b) a plurality of elongated deck members positionable in said channels for coupling said frame members together, wherein at least some of the deck members comprise a plurality of elongated elements and at least one connector connecting the elongated elements together.   
     
     
         25 . The pallet as defined in  claim 24 , wherein the elongated elements extend in spaced-apart parallel planes and wherein the at least one connector comprises a plurality of connectors for joining the elongated elements together. 
     
     
         26 . The pallet as defined in  claim 25 , wherein the frame members comprise a plurality of pallet stringers and wherein the width of the connectors is approximately equal to the width of the stringers, wherein a length of the connectors is alignable with a length of a corresponding stringer when the pallet is assembled. 
     
     
         27 . A method of manufacturing a pallet comprising:
 (a) providing a plurality of frame members formed from plastic, each of the frame members having a plurality of channels formed therein;   (b) providing a plurality of deck members formed from plastic, at least some of the deck members comprising a plurality of elongated elements joined together with at least one connector;   (c) positioning each of the deck members within a corresponding channel; and   (d) securing each of the deck members to one or more of the frame members.   
     
     
         28 . The method defined in  claim 27 , wherein the securing comprises bonding the deck members to the frame members by heat and/or sonic welding. 
     
     
         29 . The method defined in  claim 27 , wherein the securing comprises bonding the deck members to the frame members using an adhesive. 
     
     
         30 . The method defined in  claim 27 , wherein the at least one connector comprises a plurality of connectors, wherein the plurality of connectors each have a length alignable with a length of the frame members when the pallet is assembled.