Stackable pallet

Abstract

A pallet assembly includes a top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck. At least one vertical support is connected to the top deck and extends perpendicularly from a central axis below the top deck and includes stabilizing feet which extend longitudinally along a width direction of the top deck. A second interlock pattern is disposed on all or a portion of the at least one vertical support or the stabilizing feet. One of the first interlock pattern and the second interlock pattern includes one or more protrusions, while the other of the first interlock pattern and the second interlock pattern includes apertures or channels for receiving the one or more protrusions.

What is claimed: 
     
         1 . A pallet assembly, comprising:
 a top deck, the top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck;   at least one vertical support connected to the top deck and extending perpendicularly from a central axis below the top deck, the at least one vertical support comprising stabilizing feet which extend longitudinally along a width direction of the top deck; and   a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet;   wherein one of the first interlock pattern and the second interlock pattern comprises one or more protrusions and the other of the first interlock pattern and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions.   
     
     
         2 . The pallet assembly of  claim 1 , wherein the top deck and the at least one vertical support are releasably joined. 
     
     
         3 . The pallet assembly of  claim 1 , wherein the first interlock pattern comprises one or more protrusions and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions. 
     
     
         4 . The pallet assembly of  claim 1 , wherein the second interlock pattern comprises one or more protrusions and the first interlock pattern comprises one or more apertures or channels for receiving the one or more protrusions. 
     
     
         5 . The pallet assembly of  claim 1 , further comprising a plurality of vertical supports, each having a respective set of stabilizing feet. 
     
     
         6 . The pallet assembly of  claim 1 , further comprising a vertical support lacking stabilizing feet. 
     
     
         7 . The pallet assembly of  claim 1 , wherein the stabilizing feet extend longitudinally for a distance that is less than a width of the top deck. 
     
     
         8 . The pallet assembly of  claim 1 , wherein the stabilizing feet extend longitudinally for a distance that is equal to or greater than a width of the top deck. 
     
     
         9 . The pallet assembly of  claim 1 , wherein the stabilizing feet further comprise an outer sleeve and an inner sleeve which telescopically adjust for a distance that is less than, equal to, or greater than a width of the top deck. 
     
     
         10 . The pallet assembly of  claim 1 , wherein the two or more of the at least one vertical supports are connected by one or more cross braces. 
     
     
         11 . The pallet assembly of  claim 10 , wherein the one or more cross braces comprise an interlock pattern disposed on at least a portion of a cross brace surface. 
     
     
         12 . The pallet assembly of  claim 1 , wherein the top deck further comprises apertures which are configured to receive a fork on a forklift or pallet jack. 
     
     
         13 . The pallet assembly of  claim 1 , wherein the top deck and the at least one vertical support comprise the same material. 
     
     
         14 . The pallet assembly of  claim 1 , wherein the at least one vertical support and the stabilizing feet comprise the same material. 
     
     
         15 . The pallet assembly of  claim 13 , wherein the material comprises a plastic selected from the group consisting of high-density polyethylene (HDPE), polypropylene, acrylonitrile butadiene styrene, polycarbonate, and a combination thereof. 
     
     
         16 . The pallet assembly of  claim 1 , wherein the top deck and stabilizing feet are configured to be aligned by one or more tongue-and-groove connections within the apertures or channels. 
     
     
         17 . A stacked pallet system comprising:
 a first pallet assembly and a second pallet assembly, each of the first pallet assembly and the second pallet assembly comprising:   a top deck having a first interlock pattern;   at least one vertical support attached to a bottom surface of the top deck and extending perpendicular from a central axis of the top deck, the at least one vertical support comprising stabilizing feet; and   a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet;   wherein one of the first interlock pattern and the second interlock pattern comprises one or more protrusions and the other of the first interlock pattern and the second interlock pattern comprises apertures or channels for receiving the one or more protrusions; and   wherein the second pallet assembly is stacked on top of the first pallet assembly such that the first interlock pattern of the first pallet assembly mates with the second interlock pattern of the second pallet assembly.   
     
     
         18 . A method of arranging stackable pallets comprising:
 providing a plurality of pallet assemblies, the pallet assemblies each comprising a top deck having a first interlock pattern, at least one vertical support attached to a bottom surface of the top deck and extending perpendicular from a central axis of the top deck, the at least one vertical support comprising stabilizing feet; and, a second interlock pattern disposed on all or a portion of the at least one vertical support or the stabilizing feet; wherein the first interlock pattern and the second interlock pattern are complementary; and   mating the second interlock pattern of the vertical support and/or stabilizing feet of a first pallet assembly with the first interlock pattern of the top deck of a second pallet assembly.   
     
     
         19 . A pallet assembly, comprising:
 a top deck having a load bearing surface and a first interlock pattern disposed on at least a portion of the top deck;   at least one vertical support extending perpendicularly from a central axis below the top deck and, the at least one vertical support comprising stabilizing feet which extend longitudinally along a width direction of the top deck; and   a second interlock pattern disposed on at least a portion of the at least one vertical support;   wherein one of the first interlock pattern and the second interlock pattern comprise one or more protrusions and the other of the first interlock pattern and the second interlock pattern is configured to receive the one or more protrusions.   
     
     
         20 . The pallet assembly of  claim 19 , wherein the first interlock pattern comprises a continuous protrusion following a perimeter of the top deck. 
     
     
         21 . The pallet assembly of  claim 1 , wherein the assembly is configured to be transported using a conventional walk behind electric forklift. 
     
     
         22 . The pallet assembly of  claim 1 , wherein the assembly has a size of a conventional half pallet.