Abstract:
A pallet construction including a plurality of elongate extending and inter-engaging members establishing three dimensional construction with an upper platform supporting surface and a spaced apart and bottom ground supporting surface. A plasticized and environmentally sealing spray overcoat is applied over the members. Additional variants include a plurality of three dimensional and rectangular shaped support elements sandwiched between a first upper plurality of elongated members and a second plurality of lower members. A plurality of inter-engaging and overlapping locations include at least one of reduced thickness or notched locations in order to assemble into a seamless and constant width manner. The members can further exhibit any specified shape and size and can be constructed of any of a wood, steel, aluminum, bamboo, composite plastic, cardboard, foam or concrete/silicate based material.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present invention claims priority from U.S. Ser. No. 61/414,772 filed Apr. 13, 2011. 
    
    
     FIELD OF THE INVENTION 
     The present invention discloses a variety of pallet designs incorporating any of a variety of unitary or composite materials, not limited to wood, steel, aluminum, bamboo, plastic, cardboard, foam and concrete, and which combines a universally bondable plastic spray over coating for providing a durable and environmentally resistant article. 
     DESCRIPTION OF THE BACKGROUND ART 
     The prior art is well documented with examples of pallet assemblies such as which typically are constructed of cross wise extending lengths of wood or other suitable materials which are nailed or otherwise adhered together in such a fashion in order to provide an elevated load bearing surface. A problem with existing pallet assemblies is the tendency of the wood or other structural material to degrade as a result of moisture permeation, resulting in marked reduction in useful life and performance. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention discloses a pallet construction including a plurality of elongate extending, and inter-engaging members establishing three dimensional construction with an upper platform supporting surface and a spaced apart and bottom ground supporting surface. A plasticized and environmentally sealing spray overcoat is applied over the members. 
     Additional variants include a plurality of three dimensional, and rectangular shaped support elements sandwiched between a first upper plurality of elongated members and a second plurality of lower members. A plurality of inter-engaging and overlapping locations include at least one of reduced thickness or notched locations in order to assemble into a seamless and constant width manner. The members can further exhibit any specified shape and size and can be constructed of any of a wood, steel, aluminum, bamboo, composite plastic, cardboard, foam or concrete/silicate based material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: 
         FIGS. 1A-1D  depict an external plasticized spray applied over each of wood, steel, aluminum and bamboo core materials; 
         FIGS. 2A-2D  depict the plasticized spray applied over a variety of plasticized composite, cardboard, foam and concrete materials; 
         FIG. 3  is a perspective depiction of a wooden pallet exhibiting one configuration and over which is applied a highly bondable and environmentally sealing plasticized spray; 
         FIG. 4  is an enlarged corner depiction of the pallet shown in  FIG. 3  and which better depicts the application of the over spray coat; 
         FIG. 5  is a perspective view of a further configuration of wooden pallet with environmental spray overcoat; 
         FIG. 6  is a rotated underside perspective of the pallet shown in  FIG. 5 ; 
         FIG. 7  is an enlarged partial illustration illustrating a corner profile in which overlapping end portions exhibit reduced thicknesses for establishing a seamless appearance; 
         FIG. 8  is a perspective of a still further configuration of wooden pallet based upon the design of  FIG. 5  and with selected bracing members removed; 
         FIG. 9  is a rotated underside perspective of the pallet in  FIG. 8 ; 
         FIG. 10  is an enlarged partial illustration of a corner profile of the pallet and similar to that shown in  FIG. 7 ; 
         FIG. 11  is a top perspective illustration, of a further configuration of the pallet exhibit combined “X” and cross shapes components; 
         FIG. 12  is a rotated underside perspective of the pallet in  FIG. 11  and better exhibiting the plurality of three parallel extending bottom slats without additional cross bracing; 
         FIG. 13  is an enlarged partial illustration of a corner profile of the pallet in  FIG. 11  similar to prior  FIGS. 7 and 10 ; 
         FIG. 14  is an upper perspective of a Euro pallet design according to a still further embodiment; 
         FIG. 15  is an enlarged perspective of the pallet design of  FIG. 14  and further depicting mating arrangement between the upper, lower and crosswise extending pieces; and 
         FIG. 16  is a rotated underside perspective of the pallet in  FIG. 14  and illustrating a like variation of three parallel extending bottom slats similar to the variant shown in  FIG. 12 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the attached illustrations, the present invention discloses a variety of pallet designs incorporating any of wood, steel, aluminum or bamboo materials, and which combines a universally bondable plastic spray over coating for providing a durable and environmentally resistant article. The pallet configurations and materials described herein are intended to present a non-limiting selection of possible designs and it is further envisioned that other shapes and assemblies can be substituted. 
     The above said,  FIGS. 1A-1D  depict a series of applications  10 ,  12 ,  14  and  16 , respectively, of an external plasticized spray (collectively referenced by nozzle  2  for applying a coating  4 ) and applied over each of wood, steel, aluminum and bamboo core materials, respectively. As shown, the materials can exhibit any cross sectional shape or size including such, as solid wood rectangular (beam) cross section. ( FIG. 1A ), steel I-beam ( FIG. 1B ), hollow tubular aluminum rectangular member ( FIG. 5C ) and bamboo circular cross sectional member ( FIG. 1D ). 
       FIGS. 2A-2D  illustrate a series of sandwiched and irregular shaped articles, each depicting the plasticized spray applied over a variety of plasticized composite  18  (or multi layer sandwiched material as shown in  FIG. 2A ), corrugated cardboard material  20  (shown, in  FIG. 2B  and illustrating such as a multi ply construction), foam  22  (or other expanded poly based material as shown in  FIG. 2C ) and concrete (or like silicate based)  24  materials (such as exhibiting a modified trapezoidal shape depicted in  FIG. 2D ). The purpose of  FIGS. 1 and 2  is to demonstrate the unlimited variety of articles to which the plasticized spray composition (and which can include a suitable polymeric recipe along with a desired foaming/bonding agent) can be applied in a universally bonding fashion, to a wide variety of materials. 
     Referring now to  FIG. 3 , a perspective depiction at  26  of a wooden pallet exhibiting one configuration including a plurality of three linear extending members  28 ,  30 ,  32  which are interconnected by upper and lower pairs  34  &amp;  36  and  38  &amp;  40  of cross extending end members. The linear extending and cross end extending members can include any suitable planking dimensions, such as 2×4, 2×6 or the like. 
     Additional intermediate cross extending members are provided along both upper and lower surfaces of the linear members  28 ,  30  and  32  and include upper cross members  42 ,  44  and  46  (positioned in parallel spaced fashion between upper and cross members  34  and  38 ) as well as lower cross members  48  and  50  (positioned in parallel spaced fashion between lower end cross members  36  and  40 ). The upper and lower end cross members  34 ,  36 ,  38  and  40  as well as upper  42 ,  44 ,  46  and lower  48  and  50  intermediate cross members are typically narrowed slat shaped members (such as 1×6 planking). 
     The pallet is further show with a plasticized spray coating having been pre-applied with the exception of an exposed corner location associated with linear member  32  and upper/lower end cross members  34  and  36 . As previously described, the spray coating provides environmentally sealing of the pallet members. In the particular instance of wooden planking, the use of durable plasticized spray coat retards the admittance of water and mold within the cellulosic structure of the wood, this otherwise degrading the load carrying capabilities of the pallet along with increasing its overall weight. 
       FIG. 4  is an enlarged corner depiction of the pallet shown in  FIG. 3  and which better depicts the application of the over spray coat. In particular, the relative thickness application of me spray coat, which can range form a few mils up to 1/16″ or greater, is better depicted. 
     Referring now to  FIG. 5 , a perspective view  52  is shown of a further configuration of wooden pallet with environmental spray overcoat. The variant  52  differs from that shown in  FIG. 3  in that combined superimposed cross and “X” shaped portions are provided in identical upper and lower surfaces. Specifically, crows shaped portion  54  and  56 / 58  are superimposed with inner diagonal and collectively X shaped portions  60 ,  62 ,  64  and  66  as depicted. 
     Additional outer perimeter portions  68 ,  70 ,  72 ,  74 ,  76 ,  73 ,  80  and  82  extend in pairs along each of respective foot sides of the upper pallet surface. In combination, with the diagonal portions  60 ,  62 ,  64  and  66 , additional sub-cross members are respectively indicated at  84 ,  86 ,  88  and  90 . In this fashion, individual pluralities of upper and lower elongate interconnecting members establish upper and lower layers. 
     As further shown, the overlapping seam or joint locations established by the various members  54 - 90  include both, angling/beveling the edge locations of the various members, combined with suitable notching or edging of overlapping joints so as to establish a constant thickness seamless appearance. This is best shown by example in the enlarged partial illustration of  FIG. 7  and referring to the reduced thickness and seamless edge profile established, between sections  64 ,  68  and  82 . 
       FIG. 6  is a rotated underside perspective of the pallet  52  shown in  FIG. 5  and such that a substantially identical configuration of portions (compared to  54 - 90 ) is again illustrated such that a repetitive description is unnecessary. The variant  52  further includes a plurality of three dimensional shaped rectangular portions placed at midpoint and corner locations along the outer perimeter of the pallet, see at  92 ,  94 ,  96 ,  98 ,  100 ,  102 ,  104  and  106 , and combined, with a single central located, inner sandwiched three dimensional rectangular portion  108 , these providing structural support to the pallet  52  and by virtue of separating the upper and lower layers each again respectively defined by the individual pluralities of interconnecting elongate members. 
     As with the previous embodiment, the pallet members can be assembled using nails, screw, as well as alternatively through, the application of chemical or other bonding adhesives. The over-application of the durable spray coat farther compensates for any weaker or less robust fastener arrangement employed in securing together the various planking members and serves to maintain the integrity of the pallet over its useful life. 
     Referring now to  FIG. 8  is a perspective of a still further configuration  110  of wooden pallet based upon the design of  FIG. 5  and with selected bracing members removed from the underside. Specifically, interconnecting portions  54 - 90  are repeated as shown in  FIG. 5 , however, referring further to  FIG. 9  in comparison to  FIG. 6 , a selected sub-plurality of cross members are removed leaving a reduced plurality of linear extending members  112 ,  114 ,  116  and end cross members  118  and  120 . 
     Rectangular three dimensional support portions are again depicted at  92 - 108  as previously described and the underside view of  FIG. 9 , for purposes of case of illustration, does not include the reference numerals  54 - 90  shown in  FIG. 8 .  FIG. 10  again presents an enlarged partial illustration of a corner profile of the pallet and similar to that shown in  FIG. 7 . 
     Proceeding to  FIG. 11 , a top perspective illustration is shown at  122  of a further configuration of the pallet exhibit combined “X” and cross shapes components and which again repeats the arrangement of planking portions  54 - 60  depicted in each of  FIGS. 5 and 8 . The underside view of succeeding  FIG. 12  (in comparison to corresponding underside  FIG. 9  in relation to preceding  FIG. 8 ) again exhibits the three parallel extending bottom slats  112 ,  114  and  116  without additional cross bracing.  FIG. 13  is an enlarged partial illustration of a corner profile of the pallet in  FIG. 11 , again similar to prior  FIGS. 7 and 10 ; 
     Finally,  FIG. 14  presents an upper perspective illustration, at  124  of a Euro pallet design according to a still farther embodiment and which includes parallel upper slats  126 ,  128 ,  130 ,  132  and  134  and cross slats  136 ,  138  and  140  collectively defining an upper surface layer. Three rows of structural rectangular and three dimensional portions are provided, at  142 ,  144 ,  146 ,  148 ,  150 ,  152 ,  154 ,  156  and  158  and interconnect three bottom parallel extending (lengthwise) slats  160 ,  162  and  164 . 
       FIG. 15  is an enlarged perspective of the pallet design of  FIG. 14  and further depicts mating arrangement between the upper, lower and crosswise extending pieces.  FIG. 16  finally depicts a rotated underside perspective of the pallet in  FIG. 14  and illustrating a like variation of three parallel extending bottom slats similar to the variant shown in  FIG. 12 . 
     As with the previously described variants, the Euro pallet design can exhibit any specified dimensions, however one known standard provides such pallets in a sizing of 800 mm×1200 mm. Beyond the wood material disclosed, it is again understood that any suitable material construction or configuration can be employed within the scope of the invention. Also, the use and application of the plastic spray overcoat is depleted in each of the variants and the potential range of its application and material recipe is also unlimited. 
     Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains and without deviating from the scope of the appended claims.