Pallet Assembly

Abstract

A reinforced pallet assembly constructed generally of wood, including a generally planar top platform, spacers to provide apertures for a forklift, bottom runners, and is completely encapsulated by a polymeric material. The spacers may include a foam core to reduce pallet weight but not compromise strength. The bottom runners enhance pallet stability and strength. The polymeric material provides surface friction, resistance to surface damage, and overall integrity.

What is claimed is: 
     
         1 . A pallet comprising:
 a) a substantially planar top platform;   b) a plurality of spacers;   c) a plurality of bottom support runners; and   d) a polymeric coating;   
       wherein the polymeric coating is non-pigmented or non-contaminant. 
     
     
         2 . The pallet of  claim 1 , wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and about 1.5 mm. 
     
     
         3 . The pallet of  claim 1 , wherein the substantially planar top platform further comprises a foam core layer and a laminate outer layer. 
     
     
         4 . The pallet of  claim 3 , wherein the foam core layer includes expanded polystyrene (EPS) foam (25 PSI) or other lightweight material. 
     
     
         5 . The pallet of  claim 3 , wherein the laminate outer layer includes wood laminate. 
     
     
         6 . The pallet of  claim 1 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top platform and plurality of bottom runners. 
     
     
         7 . The pallet of  claim 1 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         8 . The pallet of  claim 6 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit. 
     
     
         9 . A pallet comprising:
 a) a unitary flat top deck surface with a foam core layer and a laminate outer layer;   b) a wood cross member positioned in the core layer;   c) a plurality of spacers;   d) a plurality of bottom support runners; and   e) a polymeric coating;   
       wherein the polymeric coating is non-pigmented or non-contaminant; and 
       wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and 1.5 mm. 
     
     
         10 . The pallet of  claim 9 , wherein the foam core layer includes expanded polystyrene (EPS) foam (25 PSI) or other lightweight material. 
     
     
         11 . The pallet of  claim 9 , wherein the laminate outer layer includes wood laminate having a thickness between about 2.7 mm and about 5 mm. 
     
     
         12 . The pallet of  claim 9 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top deck and plurality of bottom runners. 
     
     
         13 . The pallet of  claim 9 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         14 . The pallet of  claim 13 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit. 
     
     
         15 . A pallet comprising:
 a) a unitary flat top deck with a foam core layer and a laminate outer layer;   b) a plurality of spacers;   c) a plurality of bottom support runners; and   d) a polymeric coating;   
       wherein the polymeric coating is non-pigmented or non-contaminant; and 
       wherein the polymeric coating is applied to the outer surfaces of the pallet as a uniform spray coating having a thickness between about 1 mm and 1.5 mm. 
     
     
         16 . The pallet of  claim 15 , wherein the foam core layer includes expanded polystyrene (EPS) foam (25 PSI) or other lightweight material. 
     
     
         17 . The pallet of  claim 15 , wherein the laminate outer layer includes wood laminate having a thickness between about 2.7 mm and about 5 mm. 
     
     
         18 . The pallet of  claim 15 , wherein the plurality of spacers are wood but contain a central core hole, wherein the core hole is foam filled and centrally positioned through the long axis of the spacer, perpendicular to the horizontal planes of the top deck and plurality of bottom runners. 
     
     
         19 . The pallet of  claim 15 , wherein the polymeric coating includes a polyurea hybrid, polyurethane, or a polyurea/polyurethane blend. 
     
     
         20 . The pallet of  claim 19 , wherein the polyurea/polyurethane blend has a density of about 70 pcf, has a tensile strength of about 1800 psi, and has a tear resistance of about 304 pli at about 75 degrees Fahrenheit.