Modular pallet construction

Abstract

A modular pallet includes a deck, a plurality of beam members defining a frame for supporting the deck and each having a surface mechanically coupled with the deck, and one or more cross members mechanically coupled with each of the beam members such that the beam members have a substantially fixed spatially relationship relative to each other. The deck, beam members, and cross members can be easily assembled and disassembled.

1 . A pallet, comprising:
 a deck;   a plurality of beam members mechanically coupled with the deck; and   a first cross member bridging the beam members, the first cross member mechanically coupled with each of the beam members such that the beam members have a substantially fixed spatial relationship relative to each other.   
   
   
       2 . The pallet of  claim 1  wherein the beam members are arranged with a substantially parallel relationship and the first cross member is oriented substantially transverse to the beam members. 
   
   
       3 . The pallet of  claim 1  wherein the first cross member is secured to the beam members without mechanical fasteners. 
   
   
       4 . The pallet of  claim 1  wherein the deck is adhesively bonded to the top surface of each of the beam members. 
   
   
       5 . The pallet of  claim 1  wherein the deck comprises corrugated paper. 
   
   
       6 . The pallet of  claim 1  wherein each of the beam members includes a top surface and a side surface, and at least one of the top surface or the side surface of each of the beam members is mechanically coupled with the deck. 
   
   
       7 . The pallet of  claim 1  wherein each of the beam members includes a top surface and a first recess defined in the top surface, the first cross member includes a plurality of brackets, and each of the brackets is at least partially received in the first recess of a respective one of the beam members. 
   
   
       8 . The pallet of  claim 7  wherein each of the beam members includes a side surface, the first recess of each of the beam members extends across at least a portion of the respective side surface, and each of the brackets has a top section received in the respective first recess proximate the top surface and a side section received in the respective first recess proximate the side surface. 
   
   
       9 . The pallet of  claim 8  wherein the top section and the side section of at least one of the brackets is sized to be received in the respective first recess so that the at least one bracket does not project beyond a first plane including the top surface of the respective beam member or beyond a second plane including the side surface of the respective beam member. 
   
   
       10 . The pallet of  claim 7  wherein each of the brackets is defined by a first side section, a second side section substantially parallel to the first side section, and a top section extending between the first and second side sections to define a concavity configured to receive one of the beam members. 
   
   
       11 . The pallet of  claim 7  wherein the first cross member comprises a continuous length of metal rod stock deformed to define the brackets. 
   
   
       12 . The pallet of  claim 7  wherein the first recess in at least one of the beam members defines a slot communicating with the top surface and a bore extending through the at least one beam member, the bore having a first diameter and the slot have a first width less than the first diameter, and the at least one bracket received in the first recess of the at least one beam member having a second width greater than the first width and less than the first diameter. 
   
   
       13 . The pallet of  claim 7  further comprising:
 a second cross member bridging the beam members, the second cross member mechanically coupled with each of the beam members, and the second cross member cooperating with the first cross member to provide the beam members with the substantially fixed spatial relationship relative to each other.   
   
   
       14 . The pallet of  claim 13  wherein each of the beam members includes a second recess defined in the top surface, the second cross member includes a plurality of brackets, and each of the brackets of the second cross member is at least partially received in the second recess of a respective one of the beam members. 
   
   
       15 . The pallet of  claim 1  further comprising:
 a second cross member bridging the beam members, the second cross member mechanically coupled with each of the beam members, and the second cross member cooperating with the first cross member to provide the beam members with the substantially fixed spatial relationship relative to each other.   
   
   
       16 . A method of handling a pallet including a deck, a plurality of beam members, and at least one cross member, the method comprising:
 positioning the beam members relative to each other to define a frame for supporting the deck;   mechanically coupling the at least one cross member with each of the beam members so that beam members have a substantially fixed spatial relationship relative to each other; and   mechanically coupling the deck to a surface of each of the beam members.   
   
   
       17 . The method of  claim 16  wherein the at least one cross member includes a plurality of brackets each defined by a concavity, and wherein mechanically coupling the at least one cross member with each of the beam members further comprises:
 receiving the beam members in the concavity of each of the brackets of the at least one cross member.   
   
   
       18 . The method of  claim 16  wherein mechanically coupling the deck with each of the beam members further comprises:
 applying adhesive to the surface of each of the beam members;   contacting the deck with the adhesive; and   curing the adhesive to provide the mechanical coupling between the deck and the beam members.   
   
   
       19 . The method of  claim 16  further comprising:
 delivering a load on the pallet to a first location;   removing the deck from the beam members;   disassembling the at least one cross member from the beam members;   transporting the beam members and the at least one cross member in a disassembled condition from the first location to a second location; and   reassembling the pallet at the second location.   
   
   
       20 . The method of  claim 19  wherein the deck is coupled to a top surface of each of the beam members by adhesive, the method further comprising:
 scraping any remaining adhesive from the top surface of each of the beam members after the deck is removed.   
   
   
       21 . A method for reusing a pallet including beam members, a deck supported by the beam members, and at least one cross member mechanically coupling the beam members together, the method comprising:
 removing the deck from the beam members;   disassembling the at least one cross member from the beam members; and   transporting the disassembled beam members and the at least one cross member from a first location to a second location.   
   
   
       22 . The method of  claim 21  further comprising:
 reassembling the at least one cross member and the beam members at the second location; and   coupling a deck to the beam members.   
   
   
       23 . The method of  claim 21  further comprising:
 selling the beam members or the at least one cross member at a first price; and   repurchasing the beam members or the at least one cross member at a second price less than the first price.   
   
   
       24 . The method of  claim 21  further comprising:
 preparing the at least one cross member and the beam members for re-use at the second location;   transporting the at least one cross member and beam members to a third location;   reassembling the at least one cross member and the beam members at the third location; and   coupling another deck to the beam members.