Drywall runner pallet assembly

Abstract

A pallet assembly includes a pallet and a base. The pallet includes columns that are nestable within the base. The columns are integrally formed with the pallet. The base includes an upper platform and a lower platform with a plurality of supports disposed between the upper platform and the lower platform. The upper platform includes cut-outs for receiving the columns of the pallet. The pallet is assembled to the base. Sheets of drywall are stacked on the pallet assembly for cooling and storage. The drywall stack is subsequently shipped on the pallet, while the base remains at the manufacturer for re-use and each pallet is nestable within another pallet to create a condensed stack of pallets for economical shipment back to the manufacturer also for re-use.

1 . A pallet assembly comprising:
 a base; and   a pallet removably mounted on the base, wherein the pallet includes a deck and a plurality of columns extending downward from the deck for engagement with the base.   
   
   
       2 . The pallet assembly as recited in  claim 1 , wherein the plurality of columns are integrally molded with the deck. 
   
   
       3 . The pallet assembly as recited in  claim 1 , wherein the base and pallet are different materials. 
   
   
       4 . The pallet assembly as recited in  claim 1 , wherein each of the plurality of columns defines a first width proximate the deck and a second width spaced apart from the deck, wherein the first width is greater that the second width. 
   
   
       5 . The pallet assembly as recited in  claim 4 , wherein a width associated with each of the plurality of columns tapers from the first width to the second width, such that the pallet of one pallet assembly is nestable within the pallet of another pallet assembly. 
   
   
       6 . The pallet assembly as recited in  claim 1 , wherein the base further includes:
 an upper platform;   a lower platform; and   a plurality of supports extending between the upper platform and the lower platform.   
   
   
       7 . The pallet assembly as recited in  claim 6 , wherein the upper platform includes a plurality of cut-outs for receiving the plurality of columns. 
   
   
       8 . The pallet assembly as recited in  claim 6 , wherein the lower platform includes a first end section, a middle section, and a second end section. 
   
   
       9 . The pallet assembly as recited in  claim 6 , wherein the plurality of supports includes support cut-outs for defining fork-receiving openings between the supports and the deck. 
   
   
       10 . The pallet assembly of  claim 1 , wherein the base includes an upper platform that together with the deck forms a single support surface. 
   
   
       11 . The pallet assembly as recited in  claim 8 , wherein the deck and the upper platform are substantially flush. 
   
   
       12 . The pallet assembly as recited in  claim 1 , wherein the base includes a top surface without holes through which air can flow. 
   
   
       13 . The pallet assembly as recited in  claim 1 , wherein the pallet includes a top surface formed without holes through which air can flow. 
   
   
       14 . The pallet assembly as recited in  claim 1 , wherein each of the plurality of columns is formed without holes through which air can flow. 
   
   
       15 . A method of processing drywall including the steps of:
 a) placing a pallet in engagement with a base to form a pallet assembly, the pallet including a deck that together with a platform of the base forms a single support surface;   b) stacking individual sheets of drywall on the support surface to form a stack of drywall; and   c) removing the pallet and the drywall stack as a single unit from the base.   
   
   
       16 . The method of processing drywall as recited in  claim 12 , wherein the individual sheets of drywall are stacked when they are hot and flexible, and further including the step of:
 d) cooling the drywall on the deck and the platform prior to said step c).   
   
   
       17 . The method of processing drywall as recited in  claim 13 , further including the steps of:
 e) placing another pallet in engagement with the base after said step c); and   f) repeating steps b)-d).