Patent Publication Number: US-11661237-B1

Title: Pallet assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority to and is a non provisional of U.S. Provisional Patent Application Ser. No. 63/056,221 for a “Pallet Assembly” filed on Jul. 24, 2020, the contents of which are incorporated herein by reference in its entirety. 
    
    
     FIELD 
     This disclosure relates to the field of pallets and transportation of items thereon. More particularly, embodiments of this disclosure relate to a pallet assembly structurally reinforced by items transported on the pallet. 
     BACKGROUND 
     Various pallets exist that may be used to transport goods. For example, wooden pallets have long existed that allow items to be placed on top of and secured to the pallet for transportation of those items. Although low-cost, wooden pallets have several disadvantages. For example, wooden pallets may not be durable and may break after or during use. Further, wooden pallets may be susceptible to deteriorating, such as due to the pallets becoming wet or otherwise becoming exposed to moisture or weather conditions, thereby limiting a life span of the pallets. Wooden pallets may also become infested, such as with bugs or insects, thereby requiring additional treatment or otherwise complicating efforts to ship the wooden pallets abroad. 
     Attempts have been made to create pallets formed of other materials, such as plastics. Pallets formed of plastics and composite materials may be more durable than wooden pallets and resistant to decay and infestation. Pallets formed of plastic are therefore preferable as being re-usable or returnable. However, to make a plastic pallet stronger, the pallet must either be reinforced with additional material or support members. To make a plastic or composite pallet stronger using support members or additional reinforcing material, significant weight and cost is added to the pallet in addition to the weight of any items that are to be transported on the pallet. Increased weight of the pallet may make the pallets more difficult to move manually, and further may add to any shipping costs associated with transporting items on the pallet. Additional disadvantages of current pallets, such as pallets having reinforcing members built into the pallets, is that recycling of the pallets may involve separation of different materials in the pallet. For example, if a plastic pallet includes metal reinforcing members, recycling requires both materials to be separated which may be difficult and costly. 
     What is needed, therefore, is a pallet assembly that is structurally reinforced without adding significant weight or cost to the pallet. 
     SUMMARY 
     The above and other needs are met by a pallet assembly that is structurally reinforced without adding significant weight or cost to the pallet. In a first aspect, a pallet includes: a pallet body having a first side and an opposing second side; at least one formed portion located on the first side of the pallet body and shaped to receive a rigid elongate first item thereon, the formed portion oriented substantially along a lengthwise axis of the pallet body. When the elongate first item is substantially retained on the formed portion of the pallet body such that when the elongate first item is secured thereon, a lengthwise rigidity of the pallet body is enhanced by the rigid elongate first item. 
     In one embodiment, the pallet further includes a cap shaped to fit over the first side of the pallet body and over the rigid elongate first item located thereon. 
     In another embodiment, the formed portion comprises a channel located substantially along a length of the pallet body. In yet another embodiment, the channel is shaped to receive a barbell such that the barbell enhances a lengthwise rigidity of the pallet. In one embodiment, the channel further comprises an undercut to substantially retain the rigid elongate first item on the channel. 
     In another embodiment, the pallet body is formed of a plastic such that the pallet body is flexible along a length of the pallet body when the rigid elongate first item is not located on the formed portion of the pallet body. 
     In yet another embodiment, the pallet body further includes one or more cutouts for supporting one or more second items thereon. In one embodiment, the one or more cutouts are located such that the one or more second items are located on top of the rigid elongate first item. In another embodiment, the cutouts are shaped to receive a plurality of weight plates on top of the rigid elongate first item. In yet another embodiment, the cutouts are located such that the plurality of weight plates located thereon at least partially overlap with the at least one formed portion and the rigid elongate first item located thereon. 
     In a second aspect, a pallet includes: a pallet body having a first side and an opposing second side; at least one formed portion located on the first side of the pallet body and shaped to receive a rigid elongate barbell, the formed portion comprising a channel located substantially along a length of the pallet body and oriented substantially along a lengthwise axis of the pallet body. When the elongate barbell is substantially retained on the formed portion of the pallet body such that when the elongate barbell is secured thereon, a lengthwise rigidity of the pallet body is enhanced by the elongate barbell. 
     In one embodiment, the pallet body further includes one or more cutouts for supporting one or more weight plates thereon. In another embodiment, the cutouts are located such that the plurality of weight plates located thereon at least partially overlap with the at least one formed portion and the elongate barbell located thereon. 
     In a third aspect, a pallet includes: a pallet body having a first side and an opposing second side; at least one formed portion comprising a channel located substantially along a length of the pallet body located on the first side of the pallet body and shaped to receive a rigid elongate first item thereon, the formed portion oriented substantially along a lengthwise axis of the pallet body; a cap shaped to fit over the first side of the pallet body and over the rigid elongate first item located thereon. When the elongate first item is substantially retained on the formed portion of the pallet body such that when the elongate first item is secured thereon, a lengthwise rigidity of the pallet body is enhanced by the rigid elongate first item. The pallet body is formed of a plastic such that the pallet body is flexible along a length of the pallet body when the rigid elongate first item is not located on the formed portion of the pallet body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features, aspects, and advantages of the present disclosure will become better understood by reference to the following detailed description, appended claims, and accompanying figures, wherein elements are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein: 
         FIG.  1    shows a top plan view of a pallet assembly according to one embodiment of the present disclosure; 
         FIGS.  2  and  3    show cross-sectional side views of a pallet assembly along a length of the pallet assembly according to one embodiment of the present disclosure; 
         FIG.  4    shows a perspective view of the pallet body of the pallet assembly according to one embodiment of the present disclosure; 
         FIG.  5    shows a perspective top view of a pallet according to one embodiment of the present disclosure; 
         FIG.  6    shows a cross-sectional side view of pallet assemblies according to one embodiment of the present disclosure; 
         FIG.  7    shows a side view of a pallet assembly according to one embodiment of the present disclosure; 
         FIG.  8    is a perspective top view of a pallet assembly according to one embodiment of the present disclosure; 
         FIG.  9    is a cross-sectional top perspective view of a pallet assembly according to one embodiment of the present disclosure; 
         FIG.  10    is a top perspective view of a pallet assembly according to one embodiment of the present disclosure; and 
         FIG.  11    is a cross-sectional end view of a pallet assembly according to one embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various terms used herein are intended to have particular meanings. Some of these terms are defined below for the purpose of clarity. The definitions given below are meant to cover all forms of the words being defined (e.g., singular, plural, present tense, past tense). If the definition of any term below diverges from the commonly understood and/or dictionary definition of such term, the definitions below control. 
       FIG.  1    shows an embodiment of a pallet  100 . The pallet  100  may be formed of a plastic or composite material such that the pallet  100  is durable. The pallet  100  is adapted to transport one or more items thereon, and may be adapted to transport items that are substantially rigid. The items may be mounted and secured on the pallet  100  such that the items increase a structural rigidity or integrity of the pallet  100 . Embodiments of the pallet  100  described herein secure items on the pallet  100  such that the items may become stressed members of the pallet  100 . Other items may be located on the pallet  100  and supported by the pallet  100  and the items secured thereon. 
     As shown in  FIG.  1   , the pallet  100  includes a pallet body  102 . The pallet body  102  may be elongate and planar in shape, as shown in  FIG.  1   . For example, and as shown in  FIG.  1   , the pallet body  102  is substantially rectangular in shape, but it is also understood that the pallet body  102  may be formed into other various shapes suitable for transport of items on the pallet  100 . The pallet body  102  may be formed of a plastic or composite material. For example, the pallet body  102  is formed or molded of plastics and/or composite materials, such as high molecular weight polyethylene. A thickness of the pallet body  102  may vary along a length and across a width of the pallet body  102 . 
     The pallet body  102  is shaped to receive one or more items thereon and to secure the one or more items to the pallet  100  such that at least one of the one or more items enhance structural rigidity of the pallet  100 . Structural rigidity of the pallet may be additionally enhanced when other of the one or more items are placed on the pallet  100 . In the exemplary embodiment of  FIG.  1    and as described below, the one or more items are shown as including weightlifting and exercise equipment. However, it is also understood that other items may be suitable for use with the pallet assembly described herein wherein one or more of those items lend structural support to the pallet  100  when located on the pallet  100 . 
     Referring to  FIGS.  1  and  2   , the pallet  100  includes at least a first formed portion  104  in the pallet body  102  for receiving a first item  106  on the pallet  100 . In  FIG.  1   , the first item  106  is shown as being a trap bar or hex bar that extends substantially along a length of the pallet  100 . Although the figures show a trap or hex bar located on the pallet  100 , it is understood that a shape of the first formed portion  104  may vary depending on the item to be placed on the pallet  100 . For example, the formed portion  104  may be shaped to receive other exercise equipment, such as an elongated weight bar such as a bench press bar or a bench press bench. Although the figures illustrate the first item  106  being exercise equipment, it is also understood that various other items to be transported are suitable as the first item  106  and are not limited to exercise equipment. 
     The first formed portion  104  may be oriented along an axis that is parallel to a lengthwise axis of the pallet  100  as shown in  FIG.  1   . The first formed portion  104  may be formed along a lengthwise axis of the pallet  100  such that when the first item  106  is secured on the pallet  100  at the first formed portion  104  as discussed in greater detail below, the first item  106  structurally enhances the pallet  100  along its longest axis. For example, locating the first item  106  on the first formed portion  104  along a lengthwise axis of the pallet  100  may prevent the pallet  100  from bending or flexing along a length of the pallet  100  as described in greater detail below. Alternatively, the first formed portion  104  may otherwise be oriented on the pallet  100  suitable for transporting the first item  106 . 
     Referring to  FIG.  2   , the first formed portion  104  may be a channel, groove, or recess formed in the pallet body  102  for receiving the first item  106  on the pallet  100 . The first item  106  may be secured on the pallet  100 , such as within the first formed portion  104  of the pallet body  102 . Although reference is made to the first formed portion  104  being a channel, groove, or recess, it is also understood that the first formed portion  104  may include a plurality of channels, grooves, recesses, or other portions of the pallet body  102  that are shaped to receive at least a portion of the first item  106 . For example, less than all of the first item  106  may be located within the first formed portion  104 . The first formed portion  104  may include a plurality of locations where only a portion of the first item  106  is located within the first formed portion  104  for securing the first item  106  on the pallet  106 . 
     The first item  106  may be removably secured to the pallet body  102 . Referring again to  FIG.  2   , in one embodiment the first formed portion  104  includes an undercut  108  such that at least a portion of the first formed portion  104  extends over the first formed portion  104  for securing the first item  106  therein. The undercut  108  is shaped such that a width of the first formed portion  104  is less than a width of the first item  106  secured therein, thereby securing the first item  106  within the first formed portion  104 . The portion of the first formed portion  104  extending over the first formed portion  104  may deflect, such that the first item  106  may be readily placed within and removed from the first formed portion  104  of the pallet body  102 . 
     In other embodiments, the first item  106  may be secured in the first formed portion  104 , such as using one or more straps, fasteners, or other similar securing means. For example, a strap or other member may extend over the first formed portion  104  such that the first item  106  is prevented from moving out of the first formed portion  104 . 
     Referring again to  FIG.  1   , the pallet  100  further may include additional formed portions for securing additional items on the pallet body  102  of the pallet  100 . For example, as shown in the figures additional items may include other weightlifting or exercise equipment such as weights  110  that are located on the pallet  100 . The weights  110  may be weight plates, such as circular weight plates shaped to fit on the bar that forms the first item  106  as shown in the figures. The pallet body  102  may include one or more cutouts  112  formed thereon for maintaining the weights  110  in place on the pallet  100 . The one or more cutouts  112  may be sized to receive the weights  110  on the one or more cutouts  112 . The one or more cutouts  112  may be located such that when the weights  110  are located thereon, at least a portion of the weights  110  overlaps with the first item  106  when the first item  106  is located within the first formed portion  104  of the pallet body  102 . 
     The one or more cutouts  112  may include an upwardly extending post located at a center of the one or more cutouts  112 . The post may be shaped to fit within an inner bore formed through the weights  110  such that a position of the weights  110  on the pallet  100  is maintained. Referring to  FIG.  2   , the weights  110  may be stacked when located on the pallet  100 . 
     With further reference to  FIG.  2   , the pallet body  102  may include a sidewall projecting upwardly from the pallet body  102 . Referring to  FIG.  4   , the pallet  100  may further include a cap  114  that is shaped to fit over the pallet body  102 . In one embodiment, the cap  114  is molded having the same shape as the pallet body  102  including the cutouts or other shaped portions formed therein. Sidewalls of the cap  114  may be trimmed such that sidewalls of the cap  114  may fit over or within the sidewalls of the pallet body  102 . 
     The pallet body  102  and the cap  114  may include a plurality of notches  116  formed on outer surfaces of the pallet body  102  and the cap  114 . The plurality of banding notches  116  are shaped to receive a strap, band, or other securing means around the cap  114  and the pallet body  102  to secure the cap  114  on the pallet body  102 . When the cap  114  is secured to the pallet body  102 , items on the pallet body  102  are substantially secured between the cap  114  and the pallet body  102 . 
     Both the cap  114  and the pallet body  102  may include one or more feet  118  projecting from the cap  114  and the pallet body  102 . The feet  118  may be located such that the pallets  100  may be stacked on top of one another, as shown in  FIG.  4   . The feet  118  may be offset such that when one or more pallets  100  are stacked on top of one another, the feet  118  substantially interlock or fit together with one or more feet  118  of an adjoining pallet. The feet  118  may further have a height such that the pallet  100  is at least partially spaced above a floor surface such that the pallet  100  may be lifted, such as with a forklift. 
     Embodiments of the pallet  100  disclosed herein advantageously enable items placed on the pallet  100  to be secured such that the items enhance a strength or rigidity of the pallet, thereby reducing the need for additional structural reinforcement members that may add additional weight and cost to the pallet or increase complexity of forming the pallet. The first item  106  may fit on the pallet towards a lower portion of the pallet body  102 , while additional items are optionally secured on the pallet  100  on top of the first item  106  such that the first item  106  may support weight of the additional items. The items may be readily removed from the pallet  100  and the pallet  100  subsequently re-used for the storage of the same or similar items. The pallet  100  may further include cutouts, recesses, or other portions for storing other various items on the pallet  100 . The pallet  100  further may be returned and re-used for shipping, further reducing costs. For example, portions of the pallet body  102  may be shaped to receive other fitness equipment such as kettle bells, medicine balls, exercise straps, and other equipment. Additional items may be located, for example, within a center portion of the first item  106  if the first item  106  includes an open middle portion. 
     As shown in  FIG.  9   , the first item  106  is located on the pallet body  102  such that the first item  106  extends substantially along a length of the pallet body  102 . The first item  106  is preferably retained on the pallet body  102  such that the first item  106  lends structural rigidity to the pallet body  102 , such as along a length of the pallet. For example, the pallet body  102  may be constructed such that when the first item  106  is not on the pallet body  102 , the pallet body  102  may be flexible and formed of a relatively thin or lightweight material. When the first item  106  is retained on the pallet body  102 , the first item  106  is retained on the pallet body  102  at the first formed portion such that the first item  106  enhances a rigidity of the pallet body  102 , such as by aiding the pallet body  102  in resisting bending along a length of the pallet. Referring to  FIG.  10   , when a second item is placed on the pallet  100 , such as the one or more weights  110 , the second item is supported on the pallet body  102  and the first item  106 . The first item  106  is retained in the first formed portion  104  of the pallet body  102  to add support to the pallet  100 , as shown in  FIG.  11   . 
     The foregoing description of preferred embodiments of the present disclosure has been presented for purposes of illustration and description. The described preferred embodiments are not intended to be exhaustive or to limit the scope of the disclosure to the precise form(s) disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the disclosure and its practical application, and to thereby enable one of ordinary skill in the art to utilize the concepts revealed in the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the disclosure as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.