Rackable pallet with configurable deck height

Abstract

A pallet includes an upper structure and a lower structure. The upper structure includes an upper deck and a plurality of upper column portions projecting downward from the upper deck. The lower structure includes a plurality of lower column portions. The upper column portions and the lower column portions are configured such that the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation. Optionally, the upper deck of the pallet includes a plurality of perimeter regions into which a desired one of a plurality of inserts can be secured to produce pallets with different perimeter options.

What is claimed is: 
     
         1 . A pallet comprising:
 an upper structure having an upper deck and a plurality of upper column portions projecting downward from the upper deck; and   a lower structure having a plurality of lower column portions, wherein the upper column portions and the lower column portions are configured such that the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and wherein the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation.   
     
     
         2 . The pallet of  claim 1  wherein the lower structure includes a plurality of runners connecting lower ends of the lower column portions. 
     
     
         3 . The pallet of  claim 1  wherein the upper column portions are securable to the lower column portions at the first orientation and at the second orientation. 
     
     
         4 . The pallet of  claim 3  wherein the lower column portions each include upper support surfaces and lower support surfaces and the upper column portions each include upper support surfaces and lower support surfaces, and wherein the lower support surfaces of the upper column portions abut the upper support surfaces of the lower column portions when the upper structure is secured to the lower structure in the first orientation and wherein the lower support surfaces of the upper column portions extend downward past the upper support surfaces of the lower column portions when the upper structure is secured to the lower structure in the second orientation. 
     
     
         5 . The pallet of  claim 4  wherein the lower support surfaces of the upper column portions abut the lower support surfaces of the lower column portions when the upper structure is secured to the lower structure in the second orientation. 
     
     
         6 . The pallet of  claim 5  wherein the plurality of upper column portions and the plurality of lower column portions are configured such that one is received within the other. 
     
     
         7 . The pallet of  claim 6  wherein the plurality of upper column portions and the plurality of lower column portions are securable to one another via snap-fit connections. 
     
     
         8 . The pallet of  claim 7  wherein the snap-fit connections include a plurality of upper snap-tabs that are configured to secure the plurality of upper column portions to the plurality of lower column portions in the first orientation and wherein the snap-fit connections include a plurality of lower snap-tabs that are configured to secure the plurality of upper column portions to the plurality of lower column portions in the second orientation. 
     
     
         9 . The pallet of  claim 8  wherein the plurality of upper snap-tabs are configured such that they do not secure the plurality of upper column portions to the plurality of lower column portions in the second orientation and wherein the plurality of lower snap-tabs are configured such that they do not secure the plurality of upper column portions to the plurality of lower column portions in the first orientation. 
     
     
         10 . The pallet of  claim 9  wherein the upper deck includes a plurality of perimeter regions configured to receive one of a plurality of inserts. 
     
     
         11 . The pallet of  claim 10  further including a first insert received in one of the plurality of perimeter regions, wherein the first insert includes a textured region. 
     
     
         12 . The pallet of  claim 11  wherein the textured region includes a plurality of bosses projecting upward from a base portion. 
     
     
         13 . The pallet of  claim 11  wherein the textured region includes a plurality of longitudinal ribs extending upward from a base portion in a direction parallel to a nearest edge of the upper deck. 
     
     
         14 . The pallet of  claim 11  further including a plurality of inserts each including an elongated lip projecting upward along an outer edge in a direction parallel to a nearest edge of the upper deck. 
     
     
         15 . A pallet comprising:
 an upper deck including a plurality of perimeter regions configured to receive one of a plurality of inserts;   a plurality of inserts received in the plurality of perimeter regions; and   a plurality of upper columns extending downward from the upper deck.   
     
     
         16 . The pallet of  claim 15  wherein each of the plurality of inserts includes a textured region. 
     
     
         17 . The pallet of  claim 16  wherein each textured region includes a plurality of bosses projecting upward from a base portion. 
     
     
         18 . The pallet of  claim 16  wherein the textured region includes a plurality of longitudinal ribs extending upward from a base portion in a direction parallel to a nearest edge of the upper deck. 
     
     
         19 . The pallet of  claim 15  further including a plurality of inserts each including an elongated lip projecting upward along an outer edge in a direction parallel to a nearest edge of the upper deck. 
     
     
         20 . A method of manufacturing a pallet including:
 molding an upper structure having an upper deck and a plurality of upper column portions projecting downward from the upper deck;   molding a lower structure having a plurality of lower column portions; and   securing the plurality of upper column portions to the plurality of lower column portions in a first orientation or a second orientation, wherein the upper deck is configured at first height when the upper structure is secured to the lower structure in a first orientation and wherein the upper deck is configured at a second height when the upper structure is secured to the lower structure at a second orientation.   
     
     
         21 . The method of  claim 20  further including:
 inserting a plurality of inserts into a plurality of perimeter regions in the upper deck.