Collapsible nestable pallet

Abstract

A multi-component pallet includes a first deck and a second deck. The first deck can be configured to be removably connected to the second deck in a first position for use in the load-bearing assembled state. The first deck can also be configured to be nested with the second deck when the pallet is in the unloaded, disassembled state. The first deck and the second deck can be configured such that the volume of the pallet in the load-bearing assembled state is greater than the volume of the first deck and the second deck when they are nested in the unloaded, disassembled state.

1 . A pallet comprising: 
 a first deck and a second deck, wherein the first deck is configured to be connected to the second deck in a first position;    the first deck is configured to be nested with the second deck in a second position when the pallet is in the unloaded state; and    volume occupied by the pallet in the first position is greater than volume occupied by the pallet in the second position.    
   
   
       2 . The pallet of  claim 1 , wherein the first position is a load-bearing assembled state and the second position is a disassembled state.  
   
   
       3 . The pallet of  claim 2 , wherein the first deck further comprises a leg core and the second deck further comprises a cavity, the leg core configured to slidably mate with the cavity when the first deck is nested with the second deck to the volume of the pallet.  
   
   
       4 . The pallet of  claim 3 , wherein the first deck is configured to be connected to the second deck in the first position by slidably engaging an interlocking joint member of the first deck with an interlocking joint member of the second deck.  
   
   
       5 . The pallet of  claim 4 , wherein the first deck is configured to be nested with the second deck in the second position by be inverting the first deck and placing the first deck over the second deck whereby the volume of the pallet is reduced.  
   
   
       6 . The pallet of  claim 5 , wherein the first deck is a top deck section and the second deck is a fork strap section.  
   
   
       7 . The pallet of  claim 5 , wherein the first deck is a fork strap section and the second deck is a top deck section.  
   
   
       8 . The pallet of  claim 5 , further comprising a lock member to connect the first deck to the second deck.  
   
   
       9 . A multi-component pallet comprising: 
 a fork strap section having a slat member and a first leg core, the first leg core including a first interlocking joint member; and    a top deck section having a second slat member and a second leg core, the second leg core including a second interlocking joint member,    wherein the second leg core is configured to form an opening in the top deck section, said opening complementing the configuration of said first leg core;    wherein the top deck section may be removably coupled to the fork strap section by slidably engaging the first interlocking joint member of the first leg core with the second interlocking joint member of the second leg core to form a joint.    
   
   
       10 . The multi-component pallet of  claim 9 , further comprising a lock member to connect the fork strap section and the top deck section.  
   
   
       11 . The multi-component pallet of  claim 10 , wherein at least one of the interlocking joint members further comprises a stopping member configured to prevent the movement of the other interlocking member in one horizontal direction when the top deck section is removably coupled to the fork strap section.  
   
   
       12 . The multi-component pallet of  claim 11 , wherein the first interlocking joint member of the first leg core may be slidably engaged with the second interlocking joint member of the second leg core from only one direction.  
   
   
       13 . The multi-component pallet of  claim 12 , wherein the top deck section further comprises a plurality of slat members.  
   
   
       14 . The multi-component pallet of  claim 13 , wherein the top deck section further comprises a plurality of stringer members.  
   
   
       15 . The multi-component pallet of  claim 14 , wherein the top deck section further comprises a plurality of leg cores.  
   
   
       16 . The multi-component pallet of  claim 15 , wherein each leg core of the plurality of leg cores of the top deck section further comprises an interlocking joint member.  
   
   
       17 . The multi-component pallet of  claim 16 , wherein the fork strap section further comprises a plurality of leg cores.  
   
   
       18 . The multi-component pallet of  claim 17 , wherein each leg core of the plurality of leg cores of the fork strap section further comprises an interlocking joint member.  
   
   
       19 . The multi-component pallet of  claim 18 , wherein the plurality of leg cores of the top deck section are configured to form a plurality of openings in the top deck section, said plurality of openings in the top deck section complementing the configuration of the plurality of leg cores of the fork strap section.  
   
   
       20 . The multi-component pallet of  claim 19 , wherein the top deck section is molded as one integral component.  
   
   
       21 . The multi-component pallet of  claim 20 , wherein the fork strap section is molded as one integral component.  
   
   
       22 . The multi-component pallet of  claim 21 , wherein the fork strap interlocking joint member further comprises an undercut section formed by allowing a portion of the interlocking joint member to overhang the leg core.  
   
   
       23 . The multi-component pallet of  claim 22 , wherein the top deck interlocking joint member further comprises an undercut section formed by allowing a portion of the interlocking joint member to overhang the leg core.  
   
   
       24 . The multi-component pallet of  claim 23 , wherein the undercut section of each interlocking joint member of the top deck section is configured to receive the portion of a corresponding interlocking joint member of the fork strap section which overhangs the leg core.  
   
   
       25 . A disassembled multi-component pallet comprising: 
 a fork strap section having a first slat member and a first leg core including a first interlocking joint member; and    a top deck section having a second slat member and a second leg core including a second interlocking joint member, said second leg core configured to form an opening in the top deck section when the pallet is configured in a load-bearing state, said opening complementing the configuration of said first leg core;    wherein said top deck section may be inverted and placed over said fork strap section to nest said top deck section and said fork strap section to reduce the height of said pallet.    
   
   
       26 . The disassembled multi-component pallet of  claim 25  wherein the top deck section further comprises a plurality of leg cores.  
   
   
       27 . The disassembled multi-component pallet of  claim 26  wherein the fork strap section further comprises a plurality of leg cores.  
   
   
       28 . The disassembled multi-component pallet of  claim 27  wherein the plurality of leg cores of the top deck section are configured to form a plurality of openings in the top deck section, said plurality of openings in the top deck section complementing the configuration of the plurality of leg cores of the fork strap section.  
   
   
       29 . A multi-component pallet comprising: 
 a fork strap section,    a top deck section;    the fork strap section including a first means for providing structural support and a first joint means to enable the coupling of the fork strap section to the top deck section;    a top deck section, including a second means for providing structural support and a second joint means to enable the coupling of the fork strap section to the top deck section;    a means for preventing movement once the fork strap section has been coupled to the top deck section;    wherein said second joint means is configured to form an opening in the top deck section, said opening configured in size and shape to compliment said first joint means, so that when the pallet is disassembled, the top deck section may be inverted and placed over said fork strap section to nest said top deck section and said fork strap section to reduce the height of said pallet.    
   
   
       30 . A method for disassembling a multi-component pallet having a top deck section with a plurality of openings and a plurality of leg cores and a fork strap section with a plurality of openings and a plurality of leg cores, the method comprising the steps of: 
 removing the top deck section from the fork strap section;    inverting the top deck section; and    nesting the top deck section with the fork strap section by inserting the plurality of leg cores of the fork strap section into the plurality of openings of the top deck section.    
   
   
       31 . The method of  claim 30 , further comprising the step of removing a locking member from the multi-component pallet before removing the top deck section from the fork strap section.  
   
   
       32 . The method of  claim 31 , wherein removing the top deck section from the fork strap section further comprises slidably disengaging the top deck section from the fork strap section.  
   
   
       33 . The method of  claim 32 , further comprising disassembling a second multi-component pallet having a top deck section with a plurality of openings and a plurality of leg cores and a fork strap section with a plurality of openings and a plurality of leg cores, the method comprising the steps of: 
 removing the top deck section from the fork strap section of the second pallet;    inverting the top deck section of the second pallet; and    nesting the top deck section of the second pallet with the fork strap section of the second pallet by inserting the plurality of leg cores of the fork strap section of the second pallet into the plurality of openings of the top deck section of the second pallet.    
   
   
       34 . The method of  claim 33 , further comprising the step of nesting the pallet in the disassembled state with the second pallet in the disassembled state.  
   
   
       35 . The method of  claim 34 , wherein nesting the pallet in the disassembled state with the second pallet in the disassembled state further comprises inserting the plurality of leg cores of the top deck section of the first pallet into the plurality of openings of the fork strap section of the second pallet.  
   
   
       36 . A method for transporting an item from a point of origin to a destination with a pallet having a first deck and a second deck, the method comprising the steps of: 
 connecting the top deck section to the fork strap section in a first position;    placing an item on the top deck section of the pallet at the point of origin;    transporting the pallet and the item to the destination;    removing the item from the pallet at the destination;    removing the top deck section from the fork strap section; and    nesting the top deck section with the fork strap section in a second position, wherein the volume of the top deck section and the fork strap section in the second position is less than the volume of the top deck section and the fork strap section in the first position.    
   
   
       37 . The method of  claim 36 , further comprising transporting the top deck section and the fork strap to the point of origin, wherein the top deck section and the fork strap are connected in the second position.  
   
   
       38 . The method of  claim 37 , further comprising the step of inserting a locking member to connect the fork strap section and the top deck section.