Modular pallet

Abstract

A pallet and method of assembly of a pallet are disclosed. The pallet preferably employs a two part construction including a deck and a plurality of plastic spacers separately fabricated from the deck and coupled to the deck. The plurality of spacers may be provided in sections which are modular and are configured to be nested with each other when not assembled to a pallet. The deck may be made of simple plywood construction.

1 . A pallet, comprising:
 a deck; and   a plurality of plastic spacers separately fabricated from the deck and coupled to the deck.   
     
     
         2 . A pallet as set out in  claim 1 , wherein said plastic spacers are formed in sections and each of the spacer sections comprises:
 a substantially flat portion coupled to the deck; and   a plurality of feet extending from the substantially flat portion.   
     
     
         3 . A pallet as set out in  claim 2 , wherein each of the plurality of feet comprises a hollow body and an extrusion extending substantially through the hollow body. 
     
     
         4 . A pallet as set out in  claim 2 , wherein the plurality of feet of each spacer section form a single row. 
     
     
         5 . A pallet as set out in  claim 2 , wherein plural rows are arranged in parallel on the deck. 
     
     
         6 . A pallet as set out in  claim 2 , wherein the deck comprises a substantially flat panel made of plywood. 
     
     
         7 . A pallet as set out in  claim 2 , wherein the substantially flat portion and the plurality of feet are unitarily formed. 
     
     
         9 . A pallet as set out in  claim 1 , wherein the plurality of spacer sections are modular and are configured to be nested with each other when not assembled to a pallet. 
     
     
         10 . A pallet as set out in  claim 1 , wherein the plurality of spacers are made of high-density polyethylene (HDPE). 
     
     
         11 . A pallet as set out in  claim 2 , wherein the plurality of modular spacer sections are coupled to the deck using one or more of the following: corrosion-resistant staples, bonding using a two-part polyurethane, and bonding using an acrylic adhesive. 
     
     
         12 . A method of assembling a pallet, comprising:
 providing a deck;   separately providing a plurality of modular plastic spacer sections; and   coupling the plurality of modular plastic spacer sections to the deck to form a pallet.   
     
     
         13 . A method as set out in  claim 12 , wherein the plurality of modular spacer sections are nestable, the method further comprising: un-nesting the plurality of modular spacer sections. 
     
     
         14 . A method as set out in  claim 12 , wherein the coupling comprises using at least one of the following coupling means: corrosion-resistant staples, bonding using a two-part polyurethane, and bonding using an acrylic adhesive. 
     
     
         15 . A method as set out in  claim 12 , wherein the plurality of modular spacer sections are nestable, the method further comprising:
 decoupling the plurality of modular spacer sections from the deck; and   nesting the plurality of modular spacer sections.   
     
     
         16 . A method as set out in  claim 12 , further comprising stacking the pallet with another pallet. 
     
     
         17 . A method as set out in  claim 12 , wherein providing the plurality of modular spacer sections comprises cutting the plurality of modular spacer sections from a two-dimensional pre-manufactured structure having a matrix of feet. 
     
     
         18 . A method as set out in  claim 17 , wherein each of the plurality of modular spacer sections comprises a single row of feet. 
     
     
         19 . A method of assembling a pallet, comprising:
 providing a deck;   providing a plurality of nested modular spacer sections;   un-nesting the plurality of modular spacer sections; and   coupling the plurality of modular spacer sections to the deck.   
     
     
         20 . A method as set out in  claim 19 , wherein the modular spacer sections are made of plastic.