Drywall runner pallet assembly

Abstract

A pallet assembly includes a pallet and a base. The pallet includes columns that are nestable within the base. The columns are integrally formed with the pallet. The base includes an upper platform and a lower platform with a plurality of supports disposed between the upper platform and the lower platform. The upper platform includes cut-outs for receiving the columns of the pallet. The pallet is assembled to the base. Sheets of drywall are stacked on the pallet assembly for cooling and storage. The drywall stack is subsequently shipped on the pallet, while the base remains at the manufacturer for re-use and each pallet is nestable within another pallet to create a condensed stack of pallets for economical shipment back to the manufacturer also for re-use.

Description

BACKGROUND OF THE INVENTION

This invention relates generally to a pallet assembly for storing and transporting goods and, more particularly to a nestable pallet and base assembly used for cooling, storing and transporting drywall.

Pallets are often used to store and transport sheets of drywall. Known pallets are typically constructed of wood. Individual sheets of drywall, which are ready for shipment, are typically stiff and hard, however, when the drywall is freshly made, the individual sheets are hot and flexible. As the individual sheets of drywall are stacked on the pallet while they are still hot and flexible, the pallet provides support for the individual sheets as they cool and harden.

The stacks of individual sheets of drywall are subsequently stored and shipped on the pallets. The wood pallets are heavy, which increases shipping costs. Once the drywall is shipped on the pallets, the pallets typically are not returned, but are destroyed and disposed of

Accordingly, there is a need for pallet that provides structure during the cooling, storing and transportation process and which is reusable, recyclable and economical to manufacture.

SUMMARY OF THE INVENTION

The present invention provides a pallet assembly including a pallet and a base. The pallet, which is made from plastic, includes a deck and columns that are nestable within the base. The columns are integrally formed with the deck. The base, which is made from wood, includes an upper platform and a lower platform with a plurality of supports disposed between the upper platform and the lower platform. The upper platform includes cut-outs for receiving the columns of the pallet. The pallet is assembled to the base. Sheets of drywall are stacked on the pallet assembly for cooling and storage. The drywall stack is subsequently shipped on the pallet, while the base remains at the manufacturer for re-use.

Further, each pallet is nestable within another pallet, creating a condensed stack of pallets for economical shipment back to the manufacturer also for re-use.

These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of a pallet assembly including a pallet and a base according to one embodiment of the present invention;

FIG. 1A is an assembled view of the pallet assembly including the pallet and the base according to one embodiment of the present invention;

FIG. 2 is a detailed view of the pallet of FIG. 1;

FIG. 2A is a bottom view of the pallet of FIG. 2;

FIG. 2B is a side view of the pallet of FIG. 2 in the direction of A;

FIG. 2C is a section view through the pallet of FIG. 1 with a similar pallet nested therein;

FIG. 3 is a detailed view of the base of FIG. 1;

FIG. 4 is a side view of the assembled pallet assembly and stack of drywall of FIG. 1;

FIG. 5 is an isometric view of the pallet assembly and stack of drywall of FIG. 4; and

FIG. 6 is a top view of the pallet assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An exploded view of a pallet assembly 10 according to one embodiment of the present invention is shown in FIG. 1. The pallet assembly 10 includes a pallet 12 and a base 14 for supporting a stack of sheets of drywall 24. The pallet 12 is molded from a plastic material and includes columns 16, which are integrally formed with a deck 26. The base 14 may be constructed from wood and includes an upper platform 18A, B, C and a lower platform 20A, B, C. A plurality of supports 22 extend between the upper platform 18A, B, C and the lower platform 20A, B, C.

As illustrated in FIG. 1A, the pallet 12 is assembled to the base 14 to form the pallet assembly 10. The deck 26 of the pallet 12 rests on the upper platform 18 of the base 14. The deck 26 of the pallet 12 has a thickness that protrudes slightly above the top surface 60 of the upper platform 18; however, the deck 26 is sufficiently thin as to not create a significant impression on the hot drywall sheets (FIG. 1) after they are loaded onto the pallet assembly 10. Alternatively, the base 14 may include recesses (not shown) in the top surface 60 of the upper platform 18 that match the deck 26, such that the deck 26 rests within the recess. In this configuration, a top surface 62 of the pallet 12 would be substantially flush with the top surface 60 of the upper platform 18 of the base 14.

Further, it should be noted that the top surface 62 of the pallet 12 and the top surface 60 of the upper platform 18 of the base 14 are continuous surfaces, i.e. there are no holes through which air can flow. As illustrated in the example embodiment, there are no air holes in either the top surface 62 of the pallet 12, the top surface 60 of the upper platform 18 of the base 15, or the columns 16, which are integrally formed in the top surface 62 of the pallet 12. The absence of air holes, limits the amount of airflow beneath the stack of sheets of drywall 24 when stacked on the pallet assembly 10. This prevents the individual sheets of drywall from curing at different rates, which can be detrimental to the aesthetic appearance of the individual sheets of drywall. For example, areas that are exposed to air cure faster than areas that are not exposed to air, creating a visible flaw, such as an imprint, on a surface of the individual sheet of drywall. While this visible flaw does not affect the integrity of the individual sheet of drywall, it may generate an impression to a consumer that the individual sheet of drywall is damaged.

A detailed view of the pallet 12 is shown as FIG. 2. The pallet 12 includes a deck 26. The plurality of columns 16 are formed with the pallet 12 and extend below the deck 26. The deck 26 includes a first portion 26A and a second portion 26B and an opening 28 disposed between the first portion 26A and the second portion 26B.

FIG. 2A is a bottom view of the pallet 12. The pallet 12 includes the deck 26 and the plurality of integrally formed columns 16. The deck 26 includes the first portion 26A and the second portion 26B. The pallet 12 could be thermoformed or injection molded or made by any other suitable process. The plurality of columns 16 are located at spaced-apart positions about the periphery as illustrated, although other arrangements could be used.

As illustrated in FIG. 2B, each of the columns 16 includes a first width W₁ near a top edge 32, which is proximate the deck 26, and a second width W₂ near a distal edge 34, which is spaced away from the deck 26. The first width W₁ is wider than the second width W₂ and tapers down to the second width W₂ such that pallets 12 (in particular the columns 16) are nestable within one another for economical shipping and storage when empty. This is illustrated in FIG. 2C, where a similar pallet 12′ is stacked on and nested with the pallet 12. The columns 16′ of the upper pallet 12′ are received almost completely within the columns 16 of the lower pallet 12. This reduces the space required for storing and shipping empty pallets 12, 12′. Many similar pallets 12, 12′ could be stacked together as shown.

A detailed view of the base 14 according to the present invention is shown in FIG. 3. The base 14 includes an upper platform 18 and a lower platform 20. A plurality of supports 22 extend between the upper platform 18 and the lower platform 20. The upper platform 18 of the base 14 includes a first end section 18A, a middle section 18B, and a second end section 18C. The first end section 18A and second end section 18C include cut-outs 40 for receiving columns 16 of the pallet 12 (FIG. 2). The middle section 18B includes cut-outs 42 for receiving columns 16 of the pallet 12 (FIG. 2). The lower platform 20 of the base 14 includes a first end section 20A, a middle section 20B, and a second end section 20C.

Each of the plurality of supports 22 includes support cut-outs 44 for receiving forks of a fork truck on either side of the middle section 18B of the upper platform 18. The base 14 may be constructed of wood, metal, plastic, fiberglass composites or any other suitably durable and rigid materials.

Referring to FIGS. 4 and 5, in use, individual sheets of drywall 24, are placed upon the pallet assembly 10 to cool after production. The stack of sheets of drywall 24 rests deck 26 of the pallet 12 and the upper platform 18 of the base 14. Openings 50 are disposed between the deck 26 of the pallet 12 and the base 14 to receive forks of a fork truck. When the sheets of drywall 24 are cool and sufficiently strong and stiff such that they no longer need the support of the base 14, the fork truck inserts the forks into the openings 50 and lifts up the stack of drywall 24 and the pallet 12 for shipping. The stack of sheets of drywall 24 is shipped on the pallet 12 only. That is, the pallet 12 and the stack of drywall 24 are lifted off of the base 14 and the stack of drywall 24 is shipped on the pallet 12 while the base 14 remains at the manufacturer. Additional empty pallets 12 are subsequently placed upon the base 14 to create pallet assemblies 10 on which individual sheets of drywall 24 are placed to cool after production. The base 14 remains at the manufacturer for re-use.

The stack of drywall 24 and the pallet 12 can be stacked with other, similar pallets of stacks of drywall (not shown) and shipped to the store. The drywall may be displayed and sold from the pallet 12 at the store. The pallet 12 may be shipped back to the manufacturer for reuse after the stack of drywall 24 is sold, or may be recycled.

FIG. 6 is a top view of the pallet assembly 10. A first end portion 64A of the pallet 12 rests on the top surface 60 of the first end section 18A of the upper platform 18. A middle portion 64B of the pallet 12 rests on the top surface 60 of the middle section 18B of the upper platform 18. A second end portion 64C of the pallet 12 rests on the top surface 60 of the second end section 18C of the upper platform 18. The top surface 62 of the pallet 12 may be slightly raised in relation to the top surface 60 of the upper platform 18. Alternatively, as discussed above, the first end section 18A, the middle section 18B and the second end section 18C may include recesses (not shown) located where the first end portion 64A, middle portion 64B and the second end portion 64C respectively overlap the top surface 60 of the upper platform 18. In this configuration, the top surface 62 of the pallet 12 would be substantially flush with respect to the top surface 60 of the upper platform 18.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. There are many different configurations for plastic pallets and many variations in design, many of which would benefit from the present invention. For example, the pallet components are preferably formed of polypropylene via an injection molding process, but of course can be formed of any type of plastic applicable for the desired use. Further, the number and arrangement of supports 22 may vary according to the size of the pallet assembly 10 and the intended application for the pallet assembly 10.

Although preferred embodiments of this invention have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.

Claims

1. A pallet assembly comprising:

a base; and

a pallet removably mounted on the base, wherein the pallet includes a deck and a plurality of columns extending downward from the deck for engagement with the base.

2. The pallet assembly as recited in claim 1, wherein the plurality of columns are integrally molded with the deck.

3. The pallet assembly as recited in claim 1, wherein the base and pallet are different materials.

4. The pallet assembly as recited in claim 1, wherein each of the plurality of columns defines a first width proximate the deck and a second width spaced apart from the deck, wherein the first width is greater that the second width.

5. The pallet assembly as recited in claim 4, wherein a width associated with each of the plurality of columns tapers from the first width to the second width, such that the pallet of one pallet assembly is nestable within the pallet of another pallet assembly.

6. The pallet assembly as recited in claim 1, wherein the base further includes:

an upper platform;

a lower platform; and

a plurality of supports extending between the upper platform and the lower platform.

7. The pallet assembly as recited in claim 6, wherein the upper platform includes a plurality of cut-outs for receiving the plurality of columns.

8. The pallet assembly as recited in claim 6, wherein the lower platform includes a first end section, a middle section, and a second end section.

9. The pallet assembly as recited in claim 6, wherein the plurality of supports includes support cut-outs for defining fork-receiving openings between the supports and the deck.

10. The pallet assembly of claim 1, wherein the base includes an upper platform that together with the deck forms a single support surface.

11. The pallet assembly as recited in claim 8, wherein the deck and the upper platform are substantially flush.

12. The pallet assembly as recited in claim 1, wherein the base includes a top surface without holes through which air can flow.

13. The pallet assembly as recited in claim 1, wherein the pallet includes a top surface formed without holes through which air can flow.

14. The pallet assembly as recited in claim 1, wherein each of the plurality of columns is formed without holes through which air can flow.

15. A method of processing drywall including the steps of:

a) placing a pallet in engagement with a base to form a pallet assembly, the pallet including a deck that together with a platform of the base forms a single support surface;

b) stacking individual sheets of drywall on the support surface to form a stack of drywall; and

c) removing the pallet and the drywall stack as a single unit from the base.

16. The method of processing drywall as recited in claim 12, wherein the individual sheets of drywall are stacked when they are hot and flexible, and further including the step of:

d) cooling the drywall on the deck and the platform prior to said step c).

17. The method of processing drywall as recited in claim 13, further including the steps of:

e) placing another pallet in engagement with the base after said step c); and

f) repeating steps b)-d).