REINFORCED PALLET

Abstract

A pallet assembly has a reinforcement structure, a top deck, and a bottom deck. The reinforcement structure is formed substantially of a first material. The top deck is formed substantially of a second material, and has a generally flat platform for receiving, storing, or transporting one or more goods. The top deck also has a top pedestal portion including an upper receiving track. The bottom deck is formed substantially of a third material. The bottom deck has a generally flat base. The bottom deck also has a bottom pedestal portion including a lower receiving track. Together the upper receiving track and the lower receiving track define a channel for receiving the reinforcement structure. The top deck and the bottom deck define a plurality of apertures.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application No. 63/527,944, filed Jul. 20, 2023, which is incorporated by reference herein in its entirety.

BACKGROUND TO THE INVENTION

Pallets are flat structures designed for the transportation and support of loaded goods. Pallets can be made from a variety of materials, with common examples being wood, plastic, and metal pallets. Each of these types of pallets has advantages and disadvantages, which warehouse and shipping operators must consider when selecting appropriate pallets for specific use cases.

Wooden pallets are generally the cheapest type of pallet, capable of supporting a moderate weight load, while not being particularly durable. Plastic pallets are more expensive than wooden pallets, are lighter than wooden pallets, and generally support less weight than wooden pallets, but are more durable than wooden pallets. Metal pallets are more expensive than both wooden and plastic pallets, weigh more than both wooden and plastic pallets, but support more weight and are more durable in non-oxidizing environments than both wooden and plastic pallets.

Consequently, there is a demand for hybrid pallets. One type of hybrid pallets is a plastic pallet, reinforced with metal. Such pallets are cheaper than all-metal pallets, but can retain a large percentage of the strength of the all-metal pallets by strategically reinforcing the plastic pallets. Generally, the most important load characteristic of a pallet is the edge-racking performance, or the ability of a pallet to retain structure while resting on a rack consisting of two upright steel frames connected by two horizontal steel beams. Reinforcing a pallet to improve edge-racking performance largely improves the material performance of the pallet.

Conventional metal-reinforced plastic hybrid pallets however present other concerns. Conventional hybrid pallets have the metal reinforcing material exposed, often acting as a lower rail on the pallet, making direct contact with any rack the pallet rests upon. This exposed metal is prone to scraping, nicking, and scratching, with can remove any anti-corrosive coating on the metal, potentially allowing the metal to oxidize, rust, and become brittle. Potential designs which place the metal inside the plastic pallets risk that water will enter the plastic pallet, and be allowed to maintain sustained and continuous contact with the metal reinforcing, ultimately wicking away or dissolving anti-corrosive coatings, and causing the trapped metal to also oxidize, rust, and become brittle.

Having identified that particular issues are present when metal-reinforced plastic hybrid pallets are used, the inventors have determined that the state of the art of pallets can still be advanced.

SUMMARY OF THE INVENTION

In a first exemplary aspect, there is provided a pallet assembly. A pallet assembly has a reinforcement structure, a top deck, and a bottom deck. The reinforcement structure is formed substantially of a first material. The top deck is formed substantially of a second material, and has a generally flat platform for receiving, storing, or transporting one or more goods. The top deck also has a top pedestal portion including an upper receiving track. The bottom deck is formed substantially of a third material. The bottom deck has a generally flat base. The bottom deck also has a bottom pedestal portion including a lower receiving track. Together the upper receiving track and the lower receiving track define a channel for receiving the reinforcement structure. The top deck and the bottom deck define a plurality of apertures.

In some examples, at least a portion of the plurality of apertures are configured to receive a fork on a fork lift or pallet jack.

In some examples, the second material and the third material are the same material.

In some examples, the first material is a metal, the second material is a first plastic, and the third material is a second plastic.

In some examples, the reinforcement structure forms a quadrilateral.

In some examples, the reinforcement structure includes one or more cross braces.

In some examples, one or both of the top deck and the bottom deck cover at least a portion of the reinforcement structure. In other examples, the top deck and the bottom deck collectively fully cover the reinforcement structure.

In some examples, the top deck and the bottom deck are configured to be aligned by one or more tongue-and-groove connections. In other examples, the pallet assembly includes a locking channel formed by a flange of the top deck abutting a shoulder of the bottom deck, the locking channel configured to prevent the top deck from separating from the bottom deck. In still other examples, a first tongue-and-groove connection of the one or more tongue-and-groove connections is configured to prevent direct water ingress to the upper receiving track or the lower receiving track.

In some examples, the top deck, the bottom deck, or a combination thereof form a region for drainage or encapsulation. In other examples, the region is formed outside of a perimeter of the reinforcement structure.

In some examples, the top deck is affixed to the bottom deck, encapsulating the reinforcement structure.

In some examples, the top deck and the bottom deck snap together to form the pallet assembly.

In some examples, the first material is a metal, and the metal is corrosion susceptible.

In a second exemplary aspect, there is a top deck. The top deck is configured to be affixed to a bottom deck to encapsulate a reinforcement structure, thereby forming a pallet assembly. The top deck has a generally flat platform for receiving, storing, or transporting one or more goods. The top deck also has a top pedestal portion including an upper receiving track. The upper receiving track is configured to accept the reinforcement structure.

In some examples, the top deck further comprises a tongue. The tongue is configured to connect to a groove of the bottom deck.

In some examples, the top deck is formed substantially of plastic.

In a third exemplary aspect, there is a bottom deck. The bottom deck is configured to be affixed to a top deck to encapsulate a reinforcement structure, thereby forming a pallet assembly. The bottom deck has a generally flat base. The bottom deck also has a bottom pedestal portion including a lower receiving track. The lower receiving track is configured to accept the reinforcement structure.

In some examples, the bottom deck further comprises a groove. The groove is configured to connect to a tongue of the top deck.

In some examples, the bottom deck is formed substantially of plastic.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are provided to help explain embodiments described herein, and are not intended to limit the scope of the appended claims. Like reference numbers refer to like features.

FIG. 1 is an isometric exploded view of a pallet assembly, including a detail area depicting a reinforcement structure residing within the lower receiving track.

FIG. 2 is a detail isometric view of the pallet assembly of FIG. 1, showing in detail the relationship between the top deck, bottom deck, and reinforcement mechanism when joined together to form the pallet assembly.

FIG. 3A is an isometric view of the pallet assembly of FIG. 1.

FIG. 3B is an exploded isometric view of the pallet assembly, showing a top deck, a bottom deck, and a reinforcement structure.

FIG. 3C is a top-down view of the pallet assembly.

FIG. 3D is a bottom-up view of the pallet assembly.

FIG. 3E front view of the pallet assembly.

FIG. 3F is a side view of the pallet assembly.

FIG. 4A is an isometric view of the top deck of FIG. 1.

FIG. 4B is a top-down view of the top deck.

FIG. 4C is a bottom-up view of the top deck.

FIG. 4D front view of the top deck.

FIG. 4E is a side view of the top deck.

FIG. 5A is an isometric view of the bottom deck of FIG. 1.

FIG. 5B is a top-down view of the bottom deck.

FIG. 5C is a bottom-up view of the bottom deck.

FIG. 5D front view of the bottom deck.

FIG. 5E is a side view of the bottom deck.

DESCRIPTION OF EMBODIMENTS

The following provides a description of various exemplary embodiments of the invention, as used in the context of a metal-reinforced plastic hybrid pallet. It will be appreciated that these examples are not limiting. Other embodiments may be other hybrid pallets, such as metal-reinforced wooden hybrid pallets, or all-metal pallets which nevertheless are made up of a top deck, bottom deck, and reinforcement structure, or other applications.

FIG. 1 is an isometric exploded view of a pallet assembly 100, including a detail area depicting a reinforcement structure 115 residing within the lower receiving track 113.

The pallet assembly 100 includes three major components: a top deck 105, a bottom deck 110, and a reinforcement structure. The top deck 105 and bottom deck 110 in this example are made out of plastic, though other materials are contemplated. The reinforcement structure 115 is made out of metal (e.g., steel) though again, other materials are contemplated. The material of the reinforcement structure 115 should be sturdier than the material of the top deck 105 or the bottom deck 110. In particular, if the top deck 105, bottom deck 110, and reinforcement structure 115 are each modeled as a series of levers, where the fulcrum of each lever is over an aperture 109A-L or an edge of the bottom pedestal 112, the modeled levers constituting the reinforcement structure 115 should be able to tolerate a higher load mass before failure than the modeled levers constituting the top deck 105 or the bottom deck 110. Due to this, it is possible that, alone, the reinforcement structure 115 would deform under a given load while the top deck 105 or bottom deck 110 (or the top deck 105 and bottom deck 110 in combination) would not deform: a plastic top deck 105 and bottom deck 110 may not deform under increasing load, then may catastrophically fail, while the reinforcement structure 115 may deform under the same increasing load, while catastrophically failing at a higher load than the top deck 105 and bottom deck 110 catastrophically fail at. By combining the top deck 105, bottom deck 110, and the reinforcement structure 115, the best deformation prevention traits and catastrophic failure traits of both material (e.g., plastic, metal) can be obtained, resulting in a superior pallet assembly 100. The overall pallet assembly 100 design allows for high edge-racking capabilities, in particular when compared to a fully-plastic pallet. Edge-racking capabilities are in part defined by a load capacity where the pallet assembly 100 is minimally supported on two edges, typically found with drive-in or push-back racking.

The top deck 105 includes a generally flat platform for receiving, storing, and transporting goods. The top deck 105 also includes a top pedestal 107, which supports the top deck 105. Embedded in the top pedestal 107 are apertures 109A-L, which are configured to receive a fork on a fork lift or pallet jack, for the purpose of lifting the pallet assembly 100 and the corresponding goods loaded onto the pallet assembly 100.

The apertures 109A-L are depicted as fully embedded in the top pedestal 107, while complimentary partial apertures are depicted as embedded in the bottom pedestal 112. The apertures 109A-L can be fully embedded in the top pedestal 107, with no complimentary full or partial apertures embedded in the bottom pedestal 112. The apertures 109A-L can be fully embedded in the bottom pedestal 112, while complimentary partial apertures can be embedded in the top pedestal 107. The apertures 109A-L can be fully embedded in the bottom pedestal 112, with no complimentary full or partial apertures embedded in the top pedestal 112. Partial apertures can be embedded in the top pedestal 107, with complimentary partial apertures embedded in the bottom pedestal 112, forming full apertures 109A-L when the top deck 105 is joined to the bottom deck 110.

The top pedestal 107 also includes top stringers 106A-I, which complimentarily connect with the bottom stringers 111A-I of the bottom pedestal 112. Though nine top stringers 106A-I are depicted in a three-by-three array, any number of top stringers 106A-I and bottom stringers 106A-I are contemplated. Any top stringers 106A-I may not have a complimentary bottom stringer 111A-I, and any bottom stringer 111A-I may not have a complimentary top stringer 106A-I.

The top pedestal 107 further includes an upper receiving track 108 (not visible here, see FIG. 4C). The upper receiving track 108 is designed to accept the reinforcement structure 115 in compliment with the lower receiving track 113, encapsulating the reinforcement structure 115. Encapsulating the reinforcement structure 115 lends the strength of the reinforcement structure 115 to the pallet assembly 100, and also protects the reinforcement structure 115 from water, oxidation, rusting, or other brittling due to environmental factors.

The reinforcement structure 115 largely follows the shape of the pallet assembly 100, being near-square (but still rectangular) and largely two-dimensional. However, other reinforcement structures designs are contemplated. In particular, in the current example the reinforcement structure resides below the apertures 109A-L, taking their geometry into consideration. Other designs, which may embed the reinforcement structure into the platform of the top deck 105, or the base of the bottom deck 110, could allow for any geometry that is largely planar. Additionally, multiple reinforcement structure 115 could be used, for example embedded near the platform of the top deck 105, and near the base of the bottom deck 110.

In this example, the reinforcement structure 115 includes cross braces 116A-B, bridging perpendicularly across the reinforcement structure 115. These cross braces improve the total load the pallet assembly 100 is able to support, and also improves the tolerance to shear forces experienced by the pallet assembly 100: a heavily-loaded pallet assembly 100 carried by a pivoting fork lift can experience substantial shear force—or a pallet assembly 100 on a rack which is being loaded or incidentally moved (e.g., during an accidental collision).

The bottom deck 110 includes a generally flat base for the pallet assembly 100 to rest upon when placed on a surface or a rack. The bottom deck 110 also includes a bottom pedestal 112, which supports the top deck 105. Embedded in the bottom pedestal 112 are bottom stringers 111A-I, which complimentarily connect with the top stringers 106A-I of the top pedestal 107. The bottom stringers 111A-I connect to the top stringers 106A-I by way of snap towers 114A-T (see FIG. 5A), which snap into complimentary receptacles in the top stringers 106A-I (not shown). The snap towers 114A-T provide a robust snap together design between the top deck 105 and the bottom deck 110.

The bottom pedestal 112 further includes a lower receiving track 113. The lower receiving track 113 is designed to accept the reinforcement structure in complement with the upper receiving track 108, encapsulating the reinforcement structure 115. The lower receiving track 113 may also include drain holes or weep holes to allow any moisture or oxidizing substances to escape the encapsulating lower receiving track 113 and upper receiving track 108. Encapsulating the reinforcement structure 115 removes any metal surfaces from the usable and viewable areas of the pallet assembly 100. Other pallets have exposed corrosion-resistant metals that can be scraped, nicked, or damaged, thereby compromising their anti-corrosive coating effectiveness. The example pallet assembly 100 does not have any exposed metal surfaces, but still retains the benefits of high edge-racking performance imbued by metal. The encapsulation also prevents direct water ingress to the reinforcement structure 115, and within the upper receiving track 108 and the lower receiving track 113.

FIG. 2 is a detail isometric cross-section view of the pallet assembly 100 of FIG. 1, showing in detail the relationship between the top deck 105, bottom deck 110, and reinforcement mechanism 115 when joined together to form the pallet assembly 100. In particular, the cross-section is of the pallet assembly 100 through one of spans of the top deck 105 and bottom deck 110—meaning one of the spans between two apertures 109A-B.

The upper receiving track 108 and the lower receiving track 113 define a channel 260, within which the reinforcement structure 115 is encapsulated.

The top deck 105 and bottom deck 110 along the path of the reinforcement structure 115 are joined together by tongue-and-groove connections 205A-C. A first tongue-and-groove connection 205A is near the outside edge of the top deck 105 and the bottom deck 110. A second tongue-and-groove connection 205B is near the outside face of the reinforcement structure 115. A third tongue-and-groove connection 205 is near the inside face of the reinforcement structure 115. The tongue-and-groove connections 205A-C may each be formed of one or more sets of tongues and grooves. In particular, as shown the tongue-and-groove connections 205A-C are each double tongue and grooves, including two tongues with two complimentary grooves.

For the purposes of this disclosure, unless otherwise indicated there is no material distinction between a tongue and a groove formed by two tongues. Meaning, the top deck 105 may be considered to have two tongues in the tongue-and-groove connection 205A entering two grooves in the bottom deck 110, or the bottom deck 110 may be considered to have two tongues in the tongue-and-groove connection 205A entering two grooves in the top deck 105.

The tongue-and-groove connections 205B-C adjacent to the reinforcement structure 115 may have drain holes or weep holes, particularly in the lower grooves within the bottom deck 110. These drain holes and the channel formed by the lower grooves into which they are embedded may collectively form regions 215A-B for drainage or encapsulation, with the tongue-and-groove connection 205B including region 215A, and the tongue-and-groove connection 205C including region 215B.

The tongue-and-groove connections 205B-C prevent direct water ingress to the reinforcement structure 115. Any water which may enter in the gap between the top deck 105 and the bottom deck 110 will be blocked by the upper tongues of the top deck 105 and be directed into the regions 215A-B nestled in the grooves of the bottom deck 110. The regions 215A-B, in order to improve bonding between the top deck 105 and the bottom deck 110, may incorporate structural adhesive, high-frequency (RF) weldable materials for RF welding, compressible sealing materials, or other materials, fluids, or agents configured to bond the top deck 105 and the bottom deck 110. The bond may be water permeable, in order to allow inadvertent water present in spaces between the top deck 105 and the bottom deck 110 to egress or drain out of drain holes or weep holes in the bottom deck 110; Or, the bond may be water impermeable and fully encapsulate the reinforcement structure 115, in order to further reduce or eliminate direct water ingress to the reinforcement structure 115. The bond can be permanent, or semi-permanent, with a semi-permanent bond being breakable via the targeted application of heat, electricity, pressure, RF welding, or other physical phenomena. The bond may be along the entire surfaces of the top deck 105, bottom deck 110, and reinforcement structure 115 configured to make contact with or mate with opposing top deck 105, bottom deck 110, or reinforcement structure surfaces, or the bond may be along selective portions of particular tongue-and-groove connections 205A-C, or any combination thereof.

In addition to the tongue-and-groove connections 205A-C, which can reduce the risk of the top deck 105 and bottom deck 110 separating, especially under shear force, the pallet assembly 100 includes a locking channel 210, which largely follows the shape of the pallet assembly 100. The locking channel 210 comprises a continuum of cantilever snap joints, made up of snap hooks which catch in a snap-fit depression. In this example, the snap hooks are reinforced perpendicularly, and are located in the top deck 105—the complimentary snap-fit depressions are located in the bottom deck 110. Alternatively, the locking channel 210 can be understood as being formed by a flange 250 of the top deck 105 abutting a shoulder 255 of the bottom deck 110, where the locking channel 210 is configured to prevent the top deck 105 from separating from the bottom deck 110. The locking channel 210, in combination with the tongue-and-groove connections 205A-C, and the snap towers 114A-T and their complimentary receptacles, provide a simple yet robust snap together design.

Therefore FIGS. 1 and 2 depict a pallet assembly 100 having a reinforcement structure 115, a top deck 105, and a bottom deck 110. The reinforcement structure 115 is formed substantially of a first material. The top deck 105 is formed substantially of a second material, and has a generally flat platform for receiving, storing, or transporting one or more goods. The top deck 105 also has a top pedestal portion 107 including an upper receiving track 108. The bottom deck 110 is formed substantially of a third material. The bottom deck has a generally flat base. The bottom deck 110 also has a bottom pedestal portion 112 including a lower receiving track 113. Together the upper receiving track 108 and the lower receiving track 108 define a channel 260 for receiving the reinforcement structure 115. The top deck 105 and the bottom deck 110 define a plurality of apertures 109A-L.

In this example, at least a portion of the plurality of apertures 109A-L are configured to receive a fork on a fork lift or pallet jack. The second material and the third material are the same material. The first material is a metal, the second material is a first plastic, and the third material is a second plastic.

In this example, the reinforcement structure 115 forms a quadrilateral. The reinforcement structure 115 includes one or more cross braces 116A-B. The top deck 105 and the bottom deck 110 cover at least a portion of the reinforcement structure 115. In particular, the top deck 105 and the bottom deck 110 collectively fully cover the reinforcement structure 115.

In this example, the top deck 105 and the bottom deck 110 are configured to be aligned by one or more tongue-and-groove connections 205A-C. The assembly 100 includes a locking channel 210 formed by a flange 250 of the top deck 105 abutting a shoulder 255 of the bottom deck, the locking channel 210 configured to prevent the top deck 105 for separating from the bottom deck 110. A first tongue-and-groove connection 205B-C of the one or more tongue-and-groove connections 205A-C is configured to prevent direct water ingress to the upper receiving track 108 or the lower receiving track 113. The top deck 105, the bottom deck 110, or a combination thereof form a region 215A-B. The region 215A is formed outside of a perimeter of the reinforcement structure 115.

In this example, the top deck 105 is affixed to the bottom deck 110, encapsulating the reinforcement structure 115. The top deck 105 and the bottom deck 110 snap together to form the pallet assembly 110.

In this example, the first material is a metal, and the metal can be susceptible corrosion, and not necessarily include or rely on an anti-corrosive coating to prevent corrosion.

FIGS. 1 and 2 also depict a top deck 105. The top deck 105 is configured to be affixed to a bottom deck 110 to encapsulate a reinforcement structure 115, thereby forming a pallet assembly 115. The top deck 105 has a generally flat platform for receiving, storing, or transporting one or more goods. The top deck 105 also has a top pedestal portion 107 including an upper receiving track 108. The upper receiving track 108 is configured to accept the reinforcement structure 115.

In this example, the top deck 115 further comprises a tongue as part of a tongue-and-groove connection 205A-C. The tongue is configured to connect to a groove of the bottom deck 110 as part of the tongue-and-groove connection 205A-C. The top deck 105 is formed substantially of plastic.

FIGS. 1 and 2 further depict a bottom deck 110. The bottom deck 110 is configured to be affixed to a top deck 105 to encapsulate a reinforcement structure 115, thereby forming a pallet assembly 100. The bottom deck 110 has a generally flat base. The bottom deck 110 also has a bottom pedestal portion 112 including a lower receiving track 113. The lower receiving track 113 is configured to accept the reinforcement structure 115.

In this example, the bottom deck 110 further comprises a groove as part of a tongue-and-groove connection 205A-C. The groove is configured to connect to a tongue of the top deck 105 as part of the tongue-and-groove connection 205A-C. The bottom deck 110 is formed substantially of plastic.

FIGS. 3A-F depict the pallet assembly 100 in further detail: isometrically, exploded, top-down, bottom-up, from the front, and from the side. In particular, some apertures 109A-F are viewable from the front, while the remaining apertures 109G-L are obscured by the top stringers 106A-I and the bottom stringers 111A-I. Conversely, some apertures 109G-L are viewable from the side, while the remaining apertures 109A-F are obscured by the top stringers 106A-I and the bottom stringers 111A-I.

FIGS. 4A-E depict the top deck 105 in further detail: isometrically, top-down, bottom-up, from the front, and from the side. In particular, FIG. 4C shows the upper receiving track 108 which compliments the lower receiving track 113 and encapsulates the reinforcement structure 115.

FIGS. 5A-E depict the bottom deck 110 in further detail: isometrically, top-down, bottom-up, from the front, and from the side. In particular, FIG. 5A shows the remaining snap towers 114C-T which work collectively with the snap towers 114A-B to couple the top deck 105 to the bottom deck 110.

The geometry of the flat platform and the flat base may be elaborate and include ornamentation. Thus, the profile of the flat platform or the flat base may be interrupted at places by openings. The profile also may be affected by normal manufacturing variations, or by the addition of intentional minor variations in shape. Other alternatives and variations will be apparent to persons of ordinary skill in the art in view of the present disclosure.

The present disclosure provides examples of embodiments of a pallet that is adapted to perform at high load with low risk of oxidation. It will be appreciated that features of embodiments may be used without other features, or in different combinations, to beneficial effect. Furthermore, it will be appreciated that certain features of the embodiments may be selected for ornamental design and are not dictated by practical function. For example, the dimension of the pallet assembly, the shape of the apertures, the pattern of the flat platform and the flat base, the number, density and length of the columns of the top pedestal or bottom pedestal, and other features may be selected based to some degree or entirely according to aesthetic preferences. Accordingly, design elements of these features can be varied and selected while maintaining functionality, such that a variety of ornamental configurations are available with substantially the same function or performance.

Unless otherwise stated, any and all measurements, values, ratings, positions, magnitudes, sizes, angles, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. Such amounts are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. For example, unless expressly stated otherwise, a parameter value or the like may vary by as much as ±5% or as much as ±10% from the stated amount. The terms “substantially,” “generally,” or “fully” means that the parameter value or the like varies up to ±25% from the stated amount. The terms “generally,” or “fully” means that the parameter value may vary from an ideal value by 25%, i.e., a parameter may conform to its descriptors by as little as 75%.

The scope of protection is limited solely by the claims that now follow. That scope is intended and should be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirement of Sections 101, 102, or 103 of the Patent Act, nor should they be interpreted in such a way. Any unintended embracement of such subject matter is hereby disclaimed.

It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “containing,” “contain”, “contains,” “with,” “formed of,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises or includes a list of elements or steps does not include only those elements or steps but may include other elements or steps not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various examples for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed examples require more features than are expressly recited in each claim. Rather, as the following claims reflect, the subject matter to be protected lies in less than all features of any single disclosed example. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present concepts.

Claims

1. A pallet assembly, comprising:

a reinforcement structure, formed substantially of a first material;

a top deck, formed substantially of a second material, comprising:

a generally flat platform for receiving, storing, or transporting one or more goods, and

a top pedestal portion including an upper receiving track; and

a bottom deck, formed substantially of a third material, comprising a generally flat base, and

a bottom pedestal portion including a lower receiving track;

wherein together the upper receiving track and the lower receiving track define a channel for receiving the reinforcement structure; and

wherein the top deck and the bottom deck define a plurality of apertures.

2. The pallet assembly of claim 1, wherein at least a portion of the plurality of apertures are configured to receive a fork on a fork lift or pallet jack.

3. The pallet assembly of claim 1, wherein the second material and the third material are the same material.

4. The pallet assembly of claim 1, wherein:

the first material is a metal;

the second material is a first plastic; and

the third material is a second plastic.

5. The pallet assembly of claim 1, wherein the reinforcement structure forms a quadrilateral.

6. The pallet assembly of claim 1, wherein the reinforcement structure includes one or more cross braces.

7. The pallet assembly of claim 1, wherein one or both of the top deck and the bottom deck cover at least a portion of the reinforcement structure.

8. The pallet assembly of claim 7, wherein the top deck and the bottom deck collectively fully cover the reinforcement structure.

9. The pallet assembly of claim 1, wherein the top deck and the bottom deck are configured to be aligned by one or more tongue-and-groove connections.

10. The pallet assembly of claim 9, further comprising a locking channel formed by a flange of the top deck abutting a shoulder of the bottom deck, wherein the locking channel is configured to prevent the top deck from separating from the bottom deck.

11. The pallet assembly of claim 9, wherein a first tongue-and-groove connection of the one or more tongue-and-groove connections is configured to prevent direct water ingress to the upper receiving track or the lower receiving track.

12. The pallet assembly of claim 1, wherein:

i) the top deck,

ii) the bottom deck, or

iii) a combination thereof

form a region.

13. The pallet assembly of claim 12, wherein the region is formed outside of a perimeter of the reinforcement structure.

14. The pallet assembly of claim 1, wherein the top deck is affixed to the bottom deck, encapsulating the reinforcement structure.

15. The pallet assembly of claim 1, wherein the top deck and the bottom deck snap together to form the pallet assembly.

16. The pallet assembly of claim 1, wherein the first material is a metal, and the metal is corrosion susceptible.

17. A top deck configured to be affixed to a bottom deck to encapsulate a reinforcement structure, thereby forming a pallet assembly, the top deck comprising:

a generally flat platform for receiving, storing, or transporting one or more goods; and

a top pedestal portion including an upper receiving track, the upper receiving track configured to accept the reinforcement structure.

18. The top deck of claim 17, further comprising a tongue, configured to connect to a groove of the bottom deck.

19. The top deck of claim 17, wherein the top deck is formed substantially of plastic.

20. A bottom deck configured to be affixed to a top deck to encapsulate a reinforcement structure, thereby forming a pallet assembly, the bottom deck comprising:

A generally flat base, and

a bottom pedestal portion including a lower receiving track, the lower receiving track configured to accept the reinforcement structure.

21. The bottom deck of claim 20, further comprising a groove, configured to connect to a tongue of the top deck.

22. The bottom deck of claim 21, wherein the bottom deck is formed substantially of plastic.