STACKABLE PALLET ASSEMBLY AND COMPONENTS

Abstract

The present disclosure provides various embodiments of a stackable pallet assembly. The stackable pallet assembly may include a pallet assembly. The pallet assembly includes a plurality of insert apertures. The stackable pallet assembly may also include a plurality of stackable inserts, each of the plurality of stackable inserts is insertable into one of the plurality of insert apertures of the pallet assembly. The stackable pallet assembly may further include a plurality of stackable extenders. Each of the plurality of stackable extenders is attachable to one of the plurality of stackable inserts. The stackable pallet assembly may still further include a plurality of stacking coupler. Each of the plurality of stacking coupler is attachable to one of the plurality of stackable extenders.

Description

FIELD

This disclosure relates to transport structures or skids and components thereof, particularly, stackable pallet assemblies with quick and efficient assembly.

BACKGROUND

A pallet (also called a skid) is a flat transport structure, which supports goods in a stable fashion while being lifted by a forklift, a pallet jack, a front loader, a jacking device, an erect crane, or any other piece of equipment for moving heavy or large objects. Pallets traditionally take up floor space and require shelving or specialized pallet designs that allow for pallet stacking to use vertical space within an area. However, pallets designed for stacking are traditionally unitary pallets that are cumbersome and large, even when not in use. Therefore, there is a long sought need to find alternative solutions to pallet design that allows for pallets to be stacked on one another without unnecessarily bulky and cumbersome pallets designed specifically for stacking.

SUMMARY

In some aspects, the techniques described herein relate to a stackable pallet assembly including: a pallet assembly, wherein the pallet assembly includes a plurality of insert apertures; a plurality of stackable inserts, wherein each of the plurality of stackable inserts is insertable into one of the plurality of insert apertures of the pallet assembly; a plurality of stackable extenders, wherein each of the plurality of stackable extenders is attachable to one of the plurality of stackable inserts; and a plurality of stacking coupler, wherein each of the plurality of stacking coupler is attachable to one of the plurality of stackable extenders.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly includes a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture; wherein the plurality of stackable inserts includes a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture; wherein the plurality of stackable extenders includes a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; and wherein the plurality of stacking coupler includes a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly includes a first engagement stringer and a second engagement stringer, wherein the first engagement stringer includes the first insert aperture and the second insert aperture, and wherein the second engagement stringer includes the third insert aperture and the fourth insert aperture.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stackable inserts includes an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stackable inserts include an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the stackable inserts the one of the plurality of stackable extender extends perpendicular to the insert protrusion.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly defines a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile including an internal space and a profile wall at least partially defining the internal space.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stackable extenders are attached to a corresponding stackable insert of the plurality of stackable inserts such that each of the plurality of stackable extenders extend laterally from the pallet assembly.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stackable inserts include an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stacking couplers are configured to receive a footing of an additional stackable insert.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stackable inserts include a footing structured to fit into a stacking coupler of an additional stackable pallet assembly.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each of the plurality of stacking coupler include a coupler protrusion and each of the plurality of stackable extenders include a coupler aperture, wherein the coupler protrusion is structured to be inserted into the coupler aperture.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the first stacking coupler and the first stackable extender are unitary.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly includes: (i) a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile including an internal space and a profile wall at least partially defining the internal space; (ii) a lineal stringer having a first end, a second end, a top wall, an internal screw boss, and an embedded lineal reinforcement, the top wall of the lineal stringer defining a plurality of slots; (iii) a lineal slat having a main wall, a leg, and an embedded lineal reinforcement, a portion of the leg configured to fit into a slot of the plurality of slots of the lineal stringer, a portion of the main wall configured to sit on a portion of the top wall when the leg is pressed into the slot of the lineal stringer; and (iv) a mechanical fastener for traversing the profile wall of the lineal engagement stringer and engaging with the internal screw boss of the lineal stringer, to securably fasten the first end of the lineal stringer to the lineal engagement stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each slot of the plurality of slots of the lineal stringer corresponds to an individual lineal slat.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein each pair of slots of the plurality of slots of the lineal stringer corresponds to an individual lineal slat.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly further includes a second lineal engagement stringer and a second mechanical fastener for securably fastening the second end of the lineal stringer to the second lineal engagement stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly further includes a second lineal stringer and a third lineal stringer; wherein a second portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the second lineal stringer, a second portion of the main wall of the lineal slat configured to sit on a second portion of the top wall of the second lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer; and wherein a third portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the third lineal stringer, a third portion of the main wall configured to sit on a third portion of the top wall of the third lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer and the leg is pressed into the slot of the third lineal stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly further including: a second lineal engagement stringer; a second lineal stringer and a third lineal stringer; a second mechanical fastener for securably fastening the second end of the lineal stringer to the second lineal engagement stringer; a third mechanical fastener for securably fastening the second end of the second lineal stringer to the second lineal engagement stringer; and a fourth mechanical fastener for securably fastening the second end of the third lineal stringer to the second lineal engagement stringer, wherein a second portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the second lineal stringer, a second portion of the main wall of the lineal slat configured to sit on a second portion of the top wall of the second lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer, and wherein a third portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the third lineal stringer, a third portion of the main wall configured to sit on a third portion of the top wall of the third lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer and the leg is pressed into the slot of the third lineal stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the lineal engagement stringer and the second lineal engagement stringer sandwich the lineal stringer, the second lineal stringer, and the third lineal stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the pallet assembly further includes a plurality of mechanical fasteners for traversing the main wall of the lineal slat and engaging with the internal screw boss of the lineal stringer, to securably fasten the lineal slat to the lineal stringer.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the profile of the lineal engagement stringer further includes a multilayer composite strip orientated parallel to the profile wall as the embedded lineal reinforcement.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the lineal stringer further includes a multilayer composite strip orientated parallel to the top wall as the embedded lineal reinforcement.

In some aspects, the techniques described herein relate to a stackable pallet assembly, wherein the lineal slat further includes a multilayer composite strip orientated parallel to the main wall as the embedded lineal reinforcement.

In some aspects, the techniques described herein relate to a method of manufacturing a stackable pallet assembly including: providing a pallet assembly, wherein the pallet assembly includes a plurality of insert apertures; inserting a plurality of stackable inserts into the plurality of insert apertures of the pallet assembly; attaching a plurality of stackable extenders to the plurality of stackable inserts; and attaching a plurality of stacking coupler to the plurality of stackable extenders.

In some aspects, the techniques described herein relate to a method, wherein the pallet assembly includes a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture; wherein the plurality of stackable inserts includes a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture; wherein the plurality of stackable extenders includes a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; and wherein the plurality of stacking coupler includes a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

In some aspects, the techniques described herein relate to a method, wherein the pallet assembly includes a first engagement stringer and a second engagement stringer, wherein the first engagement stringer includes the first insert aperture and the second insert aperture, and wherein the second engagement stringer includes the third insert aperture and the fourth insert aperture.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stackable inserts includes an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stackable inserts include an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

In some aspects, the techniques described herein relate to a method, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the plurality of stackable inserts, the one of the plurality of stackable extenders extends perpendicular to the insert protrusion.

In some aspects, the techniques described herein relate to a method, wherein the pallet assembly defines a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile including an internal space and a profile wall at least partially defining the internal space.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stackable extenders are attached to a corresponding stackable insert of the plurality of stackable inserts such that each of the plurality of stackable extenders extend laterally from the pallet assembly.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stackable inserts include an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stacking couplers are configured to receive a footing of an additional stackable insert.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stackable inserts include a footing structured to fit into a stacking coupler of an additional stackable pallet assembly.

In some aspects, the techniques described herein relate to a method, wherein each of the plurality of stacking coupler include a coupler protrusion and each of the plurality of stackable extenders include a coupler aperture, wherein the coupler protrusion is structured to be inserted into the coupler aperture.

In some aspects, the techniques described herein relate to a method, wherein the first stacking coupler and the first stackable extender are unitary.

The aforementioned embodiments are but a few examples of configurations of the systems, apparatuses, and methods disclosed herein. Further understanding and a detailed coverage of the embodiments follows herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present disclosure will be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, with emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. It should be recognized that these implementations and embodiments are merely illustrative of the principles of the present disclosure. Therefore, in the drawings:

FIG. 1A is a perspective view of an illustration of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 1B is a perspective view of an exploded illustration of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 1C, a perspective view of an illustration of the example pallet assembly of FIG. 1B organized as a kit and ready to be shipped in a box along with a box of mechanical fasteners, in accordance with various embodiments of the present disclosure;

FIG. 2A is a side view of an illustration of an example lineal engagement stringer, or of a lineal stringer, of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 2B is a side view of an illustration of an example lineal slat of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 2C is a side view of an illustration of another example lineal engagement stringer, or of another example lineal stringer, of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 2D is a perspective view of an illustration of an example target insert of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 2E is a side view of a partial, exploded illustration of an example corner of an example frame of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 3 is a perspective view of a partial illustration of an example corner of an example frame of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 4A is a cross-sectional view of a partial, exploded illustration of an example corner of an example frame of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 4B is a cross-sectional view of a partial illustration of an example corner of an example frame of an example pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 5 is an exploded view of a stackable pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 6 is an assembled view of a stackable pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 7 illustrates multiple stackable pallet assemblies stacked on one another, in accordance with various embodiments of the present disclosure;

FIG. 8 is a stackable insert assembly to be used with a stackable pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 9 is an exploded view of the stackable insert assembly of FIG. 8, in accordance with various embodiments of the present disclosure;

FIGS. 10A and 10B illustrate additional views of the stackable insert assembly, in accordance with various embodiments of the present disclosure;

FIG. 11 illustrates an end view of a pallet used with a stackable pallet assembly, in accordance with various embodiments of the present disclosure;

FIG. 12 illustrates a portion of a stackable insert to be inserted into the pallet to allow the pallet to be stackable, in accordance with various embodiments of the present disclosure;

FIGS. 13A and 13B illustrate an end view of two different example stackable extenders used with a stackable pallet assembly, in accordance with various embodiments of the present disclosure; and

FIG. 14 is an end view of the stackable insert in which the stackable extender of FIG. 12 is inserted, in accordance with various embodiments of the present disclosure.

DETAILED DESCRIPTION

The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

Throughout this specification and the claims, the terms “comprise,” “comprises,” and “comprising” are used in a non-exclusive sense, except where the context requires otherwise. Likewise, the term “includes” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

I. Example Use Case Scenarios

The lack of a single international standard for pallets causes substantial continuing expense in international trade. A single standard is difficult because of the wide variety of needs a standard pallet would have to satisfy. However, due to the International Plant Protection Convention (IPPC), most pallets shipped across national borders must be made of materials that are incapable of being a carrier of invasive species of insects and plant diseases. Pallets made of raw, untreated wood for example are not considered phytosanitary compliant. Moreover, wood pallets can pose serious bio-hazard risks as they are susceptible to bacterial and chemical contamination, such as E. coli problems in food and produce transportation, and even insect infestation.

To be phytosanitary compliant, wood pallets (or other wood packaging material) must meet debarked standards and must be treated by either of the following means under the supervision of an approved agency: heated to achieve a minimum core temperature of about 56.0° C. (132.8° F.) for at least 30 minutes; or fumigated with methyl bromide (except within all EU member states).

Pallets (also described as pallet assemblies herein) made of non-wood materials such as steel, aluminum, plastic, engineered wood products, such as plywood, oriented strand board, or corrugated fiberboard, or as shown and described herein do not need IPPC approval, and are considered to be exempt from certain phytosanitary regulations. Despite the above, the production of pallets accounts for about 43.0% of hardwood and about 15.0% of softwood usage in the U.S.

The reason for this is simple: the cheapest pallets are made of softwood and are often considered expendable, to be discarded as trash along with other wrapping elements, at the end of transport from one location to another. These pallets are simple stringer pallets, and able to be lifted from two sides.

Slightly more complex, hardwood block pallets, plastic pallets, and metal pallets can be lifted from all four sides. These costlier pallets usually require a deposit and are returned to the sender or resold as used. Many “four way” pallets are color-coded according to the loads they can bear, and other attributes.

Synthetic pallets are often made of synthetic or recycled materials. They are usually durable, long-lasting, chemically inert, and are typically weather, water, rot, and corrosion-resistant. However, they usually involve relatively complex and expensive manufacturing methods for mass production when compared to wood or semi-organic pallets for the same strength and stability.

As such, in at least one aspect, the disclosure herein is directed to improved transport structures or skids, in particular, to pallet assemblies and pallet components, and to improved methods of producing and assembling the same. In the same vein, the lessons and techniques disclosed herein are applicable to any transport structure or support structure.

II. Systems and Methods

In one aspect, the transport structure or skid according to the present disclosure is a multi-component system that allows for rapid assembly, use, and/or disassembly of the structure. The transport structure or skid, in one aspect, includes a plurality of extruded or pultruded components that are free of biological activity and exempt from phytosanitary regulations or equivalent (herein referred to as “inert”). These components can be easily transported (stacked or nested, for example) and assembled on site. In another aspect, the transport structure or skid is a pallet assembly of the stringer type, as is understood in the art. In another aspect, the pallet assembly is a block type pallet assembly, as is understood in the art, or any other type of pallet assembly (e.g., skid pallets, carrier pallet, flush pallet, perimeter base pallet, two-way or four-way) made possible with the inert, extrusion or pultrusion components according to the present disclosure.

In one aspect, the pallet assembly according to the present disclosure includes an inert frame and one or more inert support surfaces attached thereto. The pallet assembly, in one aspect, includes a frame formed by two, engagement structures (or “engagement stringers”, as referred to herein) having a plurality of perpendicular engagement structures or “stringers” therebetween and engaged, respectively, to each engagement stringer. The frame may be formed by block components or any other type(s) of components called for by the different types of pallet assemblies. Moreover, the frame or the frame components, in another aspect, may be further processed (e.g., cut, sheared, sawed, etched, chamfered, notched, bent, drilled, bored, built-up, chemically prepared, etc.) as need. Furthermore, the frame or the frame components may be further processed to include internal structures (embedded or removable/replaceable) or target inserts that are the same or a different material, for example, than the frame or the frame components. In one aspect, the one or more support surfaces are a plurality of deck boards or top slats supported and retained/held directly by the frame. The deck board(s) or top slats may include a structure that is complementary to a feature defined by the frame and that allows the deck board(s) or top slats to mate with and be held by the frame. In another aspect, the pallet assembly demands fasteners only for assembling the frame. In another aspect, the pallet assembly has optional or non-optional fasteners for attaching the deck board(s) or top slats to the frame for added rigidity and stability.

In one aspect, the stringers and the top slats are each lineal construction members produced from an extrusion or pultrusion manufacturing process using inert materials. The components for the pallet assembly in the form of lineal members may be made at least in part of polymeric materials or equivalent, e.g., low-density polyethylene (LDPE) (a chemically inert, flexible, insulator), high-density polyethylene (HDPE) (inert, thermally stable, tough and high tensile strength); polypropylene (resistant to acids and alkalis, high tensile strength); polyvinyl chloride (PVC) (insulator, flame retardant, chemically inert); polychlorotrifluoroethylene (PCTFE) (stable to heat and thermal, high tensile strength and non-wetting); polyamide (Nylon) (high melting point, excellent abrasion resistance); polyethylene terephthalate (PET) & (PETG) (High strength and stiffness, broad range of use temperatures, low gas permeability), etc. The components for the pallet assembly also may be made of recycled materials or may incorporate internal reinforcement such as embedded reinforcement fibers as is understood in the art or multilayer composite strips according to the present disclosure. The components for the pallet assembly, in another aspect, may be formed entirely of rolled metal, in particular, rolled steel or steel alloys or sheet metal. The components for the pallet assembly, in another aspect, may be formed of “color-blend” recycled plastics or polymers as is known in the art. The components for the pallet assembly, in another aspect, may be formed of scrap carbon fiber, and fiber glass and glass fibers, as well as any other polymers and/or any other natural (e.g., plant-based or plant derived) or non-natural fiber(s).

The engagement stringers, in one aspect, serve to receive and hold the only mechanical fasteners demanded by the pallet assembly (for securably attaching the stringers). In another aspect, the pallet assembly calls for mechanical fasteners for the top slats and/or any other component of the assembly (e.g., any other slats, the target inserts). In another aspect, the stringers define a slot(s) for receiving and holding the top slats. In another aspect, the components for the pallet assembly include bottom slats and the stringers also define a slot(s) for receiving and holding the bottom slats opposite the top slats. In another aspect, each of the stringers defines a targets to facilitate engagement of the pallet assembly with lift, move, and/or transport equipment.

In particular, in one aspect, each of the engagement stringers and/or each of the stringers includes a screw boss(es) to receive the assembly screws. In another aspect, the screw boss(es) and assembly screws help to securably attach each of the stingers, respectively, to each of the engagement stringers to form the frame. Importantly, assembly screws may be driven into the screw boss(es) that are exposed at the ends of the stringer. The assembly screws also may be driven (e.g., from the side(s) or from within at any point along the length of the stringer, for example, into the internal screw boss (the entire screw boss extending along a length of the stringer).

In one aspect, each of the slats is configured as a flat lineal platform having two legs. In this way, the cross-section of the slat along its length is generally II-shaped. Moreover, each of the legs of the slat is configured to fit (e.g., loosely fit, friction fit, press fit, snap fit, wedge fit) into each of the slots defined by the stringers. As such, the slats are supported and held directly by the stringers of the frame, and the slats provide a flat support surface for the pallet.

In one aspect, the pallet assembly and/or the pallet component(s) incorporate or is made of a non-homogeneous composition of matter having both compressive strength and stiffness which enables it to be used as a substitute for wood in a wide variety of applications. In another aspect, the structural composite for the pallet component(s) according to the present disclosure can substitute for other materials with higher strength modulus than wood, such as aluminum. In another aspect, the pallet assembly and any of the pallet assembly component(s) described herein incorporate(s) one or more multilayer composite strip(s) that are made of or are inclusive of the non-homogenous composition of matter according to the present disclosure.

In particular, in one aspect, the pallet assembly and/or the pallet component(s) are engineered, meaning that its exterior shape and the choice of its external or internal features or components (e.g., screw boss(es), top guide(s), screw line(s)) and their locations and shapes are based at least in part on the demands as specified herein. The pallet assembly and/or the pallet component(s) may be extruded or pultruded lineal composite structures produced with embedded reinforcement(s) that are spaced away from the neutral axis, analogous to the flanges on and I-beam, or asymmetrically situated, in order to provide increased strength and stiffness in one or both axes perpendicular to the cross-section. Because such a structural composite may be designed for load-bearing, the composition is referred to herein as a structural composite.

In one aspect, the pallet assembly and/or the pallet component(s) incorporate or is made of a structural polymeric composite including a stiffening layer(s). The composite may be manufacturing via a continuous extrusion pultrusion method in which the stiffening layer is pulled through a cross-head die as a polymer(s) is/are extruded over it. The stiffening layer may include a film or textile carrier, a filler of carbon fibers, fiberglass, and organic fibers or minerals forming a mat. A binder may be dispersed over the mat and a second carrier applied. The mat may be subjected to heat and pressure to soften the carriers and binder so they penetrate into the interstices of the filler and binds mechanically with them and the carriers and binder bind chemically with each other to form the stiffening layer. A polymer may then be extruded over the stiffening layer, which may be used flat, provided with holes or punches for composite action with the polymer, formed into profile, or segmented to provided spaced-apart stiffening layers.

In one aspect, the pallet assembly and/or the pallet component(s) incorporate or is made of a structural polymeric composite including at least one stiffening layer that increases the stiffness of the finished structural composite. A stiffening layer is incorporated into a polymeric extrusion either by extruding the polymer onto the stiffening layer so that the stiffening layer is on one side and the polymer on the other and therefore the stiffening layer is visible from the exterior, or by extruding it so that the polymer partly or wholly surrounds the stiffening layer, in which case the stiffening layer may not be visible from the exterior.

In one aspect, the pallet assembly and pallet component(s) incorporate a multilayer composite strip(s) having a first polymeric layer, a first mesh layer, a composite layer of shredded fibrous material (carbon fiber, bast fiber, etc.) and polymeric material, and a second mesh layer, and a second polymeric layer. The multilayer composite strip is formed by heating, cooling, and/or compressing, including rolling and stretching to form a rigid composite strip that may be further mechanically or chemically bonded to other polymers or building materials so as to increase stiffness and restrain lateral movement. Such composite strip is often comprised of the first polymeric layer consisting of PET, and a vinyl or metal mesh layer, wherein the PET is melted into the mesh layer, and forms a receiving layer in which fibrous material such as chopped carbon fiber may be applied, and said second mesh layer and second polymeric layer covering the fibrous material, all of which is rolled and heated to form a composite strip that provides restraint in all directions and increased rigidity.

The multilayer composite strip may further provide impact resistance and crush resistance, and allows for strengthening and hardening the pallet assembly as disclosed herein. In one aspect, a pallet assembly may be utilized to move heavy metallic items such as ammunition, weapons, or other metallic items that would cause sag or creep in the components. Applying the multilayer composite strip helps to increase working capacities, and depending on the size of the multilayer composite strip, may double the working capacity of wooden pallets (1,000 kilograms).

In one aspect, the pallet assembly and pallet component(s) incorporate a multilayer composite strip(s) having a first polymeric layer with a layer height ranging from between about 0.23 mm to about 1.1 mm; a first mesh layer, wherein at least about 20.0 percent of the first mesh layer is a void region; a composite layer of shredded fibrous material and polymeric material, wherein the shredded fibrous material is of an average length between about 5.0 mm and about 50.0 mm, and the polymeric material has a granular size from between about 50.0 microns to about 2000.0 microns prior to heating; a second mesh layer, wherein at least about 20.0 percent of the second mesh layer is a void region; and a second polymeric layer with a layer height from between about 0.23 mm to about 1.1 mm.

In one aspect, the pallet assembly and pallet component(s) incorporate polyvinyl chloride (PVC) and/or recycled PVC.

In one aspect, the pallet assembly and pallet component(s) incorporate polyamides.

In one aspect, the pallet assembly and pallet component(s) incorporate a shredded fibrous material, for example, shredded carbon fiber.

In one aspect, the pallet assembly and pallet component(s) incorporate a shredded fibrous material, for example, shredded fiberglass.

In one aspect, the pallet assembly and pallet component(s) incorporate a shredded fibrous material, for example, shredded bast fibre.

In one aspect, the multilayer composite incorporates a first polymeric layer and a second polymeric layer of polyethylene terephthalate (PET) or polyethylene terephthalate glycol (PETG).

In one aspect, the multilayer composite incorporates a first polymeric layer of PVC and/or recycled PVC.

In one aspect, the multilayer composite incorporates a first polymeric layer further including polyamides.

In one aspect, the multilayer composite incorporates a first mesh layer and a second mesh layer having a window size between 1 mm to 12 mm.

In one aspect, the multilayer composite incorporates a shredded fibrous material, for example, shredded carbon fiber.

In one aspect, the multilayer composite incorporates a shredded fibrous material, for example, shredded fiberglass.

In one aspect, the multilayer composite incorporates a shredded fibrous material, for example, shredded bast fibre.

In one aspect, the multilayer composite incorporates a third mesh layer, a second composite layer of the shredded fibrous material and the polymeric material, and a third polymeric layer, the second composite layer being of a different shredded fibrous material than the first composite layer.

In one aspect, the multilayer composite incorporated into pultruded or extruded pallet components, and wherein the multilayer composite strip(s) is/are between about 1.0 mm to about 20.0 mm in height and up to about 550.0 mm in width.

In some aspects, the multilayer composite described herein, wherein the first and second mesh layer have a tensile strength of 9,000.0 psi.

In some aspects, the multilayer composite described herein, wherein the multilayer composite is water resistant and noncorrosive.

In some aspects, the multilayer composite described herein, wherein the first polymeric layer, the first mesh layer, the composite layer, the second mesh layer, and the second polymeric layer are integrated to form a solid layer.

In one aspect, the multilayer composite incorporates a first polymeric layer with a layer height ranging from between about 0.23 mm to about 1.1 mm; a first mesh layer of fiberglass, wherein at least about 20.0 percent of the first mesh layer is a void region; a composite layer of shredded fibrous material and polymeric material, wherein the shredded fibrous material is of an average length between about 5.0 mm and about 50.0 mm, and the polymeric material has a granular size from between about 50.0 microns to 2000.0 microns prior to heating; a second mesh layer of fiberglass; and a second polymeric layer with a layer height from between about 0.23 mm to about 1.1 mm.

Referring to methods herein, in one aspect, a method of assembling a pallet is disclosed. In one aspect, the method comprises providing a lineal engagement stringer, a lineal stringer, a lineal slat, and providing a mechanical fastener. The method also comprises, in another aspect, securably fastening a first end of the lineal stringer to the lineal engagement stringer and pressing a leg of the lineal slat into a slot of the lineal stringer such that a portion of a main wall of the lineal slat sits on the portion of the top wall of the lineal stringer.

In one aspect, a method of using the pallet components is disclosed. In another aspect, the pallet components are stacked or nested and transported in a box. The stacked and/or nested pallet components conserve space and allow for ready and fast assembly on site.

III. With Reference to the Figures

U.S. patent application Ser. Nos. 18/451,636, and 18/143,185 are assigned to the Applicant of the present application, and are incorporated herein in their entirety by reference.

The term “extruded” is used herein for convenience but engagement stringers, stringer, and slats may be formed in any way customary in the industry, for example, pultruded and co-extruded with other materials. Resin fusion and vacuum fusion methods are also envisioned.

The term “lineal” is used herein to refer to an extruded pallet component having a uniform cross section perpendicular to its major dimension which major dimension is much longer than its other two dimensions; that is, the plane of any cross section perpendicular to the major dimension of the pallet component is defined by a line parallel to the major dimension.

The term “non-homogeneous” as used herein means that at least some of the constituents are concentrated within the structural composite rather than being homogeneously dispersed.

The term “screw boss” is a physical structure that grips the threads of a screw being driven into it so that, once the screw has been inserted into or through the screw boss, the screw boss resists the removal of the screw more when the screw is pulled than when the screw is unscrewed.

An “insertable screw boss” is a screw boss that has been separately extruded, molded, cast, forged, or welded so that it can be inserted into a channel and is otherwise functionally the same as a screw boss extruded as an integral part of that channel, but allowing for further strengthening or reinforcing.

A “mechanical fastener” is a mechanism or structure that helps to fasten to items or two components together, and may include but is not limited to screws, nails, bolts, pegs, mating structures, snap or button mechanisms, etc.

Accordingly, a user, a business, a military contractor, and/or any of the armed services can affectively manufacture, stack/nest, assemble, use, disassemble, store, and/or recycle the pallet components for the pallet assembly based on the systems and methods of the present disclosure. The pallet components and the resulting pallet assemblies according to the present disclosure are lighter, stronger (i.e., can hold more total weight than a comparably structured stringer pallet, for example) and take up less space than conventional pallet components or pallet assemblies. The pallet components and the resulting pallet assemblies according to the present disclosure allow for ready and efficient transport of pallet components on site, as needed, and rapid assembly/disassembly and use of those components and resulting pallets. All these advantages made possible with readily-available and/or recycled inert materials that are not at risk for chemical or biological impregnation or infestation.

Referring now to FIG. 1A, a perspective view of an illustration of an example pallet assembly according to the present disclosure is shown. In particular, in FIG. 1A there is shown a multi-component, stringer type, two-way pallet assembly 100 assembled from a plurality of extruded lineal components made of inert materials, namely, recycled PVC and fiber.

As illustrated in FIG. 1A, the pallet assembly 100 includes a frame 101 and a support surface 120 attached to the frame 101. More specifically, in FIG. 1A, the frame 101 includes two or more engagement stringers 102a, 102b, in particular, a first engagement stringer 102a arranged opposite and parallel to a second engagement stringer 102b, and a plurality of perpendicular stringers 110a, 110b, 110c engaged, respectively, to each of the engagement stringers 102a, 102b. Moreover, and with further specificity, each of the plurality of perpendicular stringers (in particular, each of a first stringer 110a, a second stringer 110b, and a third stringer 110c, which are arranged in parallel) of the frame 101 has a first end and a second end, and each first end 111a, 111b, 111c of the stringers 110a, 110b, 110c is engaged to the first engagement stringer 102a and each second end 112a, 112b, 112c of the stringers 110a, 110b, 110c is engaged to the second engagement stringer 102b. Each of the plurality of stringers 102a, 102b, 110a, 110b, 110c also is processed to include two or more cut-out targets, in particular, a first target 114a and a second target 114b each configured to receive an injection molded target insert 150a, 150b to reinforce the perpendicular stringer and to facilitate lifting of the resulting pallet assembly 100 by forklift. Each of the plurality of perpendicular stringer also is processed to include a plurality of surface features or slots 116 (best seen in FIG. 4A) that allows the support surface 120 to mate with and be held by the frame 101.

Depending on the embodiment, additional perpendicular stringer may be part of the pallet assembly 100 and be similarly situated and engaged between the engagement stringers 102a, 102b (i.e., the engagement stringers 102a, 102b being longer and/or the spacing of the perpendicular stringers being different than that illustrated). Furthermore, depending on the embodiment, additional engagement stringers (and/or longer mechanical fasteners 140, as discussed in greater detail herein; see FIG. 3) may be part of the pallet assembly 100, and used to double-up or reinforce the first engagement stringer 102a and/or the second engagement stringer 102b. Moreover, the frame or the frame components may be further processed (e.g., cut, sheared, sawed, etched, chamfered, bent, drilled, bored, built-up, chemically prepared, etc.). Furthermore, each of the engagement stringers 102a, 102b, each of the perpendicular stringers 110a, 110b, 110c and/or each of the top slats 121 may incorporate embedded reinforcement fibers, strands, or rebar-like lineal structures or multilayer composite strip(s) (as discussed in greater detail herein; see FIGS. 2C, 2E) according to the present disclosure. Depending on the embodiment, each of the engagement stringers 102a, 102b, each of the perpendicular stringer, and/or each of the top slats 121 may be formed entirely of rolled metal instead of being an extrusion or pultrusion product.

Returning to FIG. 1A, the support surface 120 includes a plurality of top slats 121 configured to be engaged/retained and directly supported by the plurality of perpendicular stringer of the frame 101. In particular, in FIG. 1A, each of the top slats 121 also is configured as a flat lineal platform having two legs 122 and having a cross-section along its length, L, that is generally II-shaped, and complementary to the slots 116 defined by each of the perpendicular stringer. As such, each of the legs 122 of each of the top slats 121 is configured to fit into each of the slots 116. The top slats 121, in this way, are supported and held directly by the frame 101. The top slats 121 also provide a stable and secure flat support surface 120.

Referring now to FIG. 1B, a perspective view of an exploded illustration of an example pallet assembly according to the present disclosure is shown. In particular, in FIG. 1B, there is shown a multi-component, stringer type, two-way pallet assembly 200 having an engagement stringer 202a arranged opposite and parallel to a second engagement stringer 202b; and a first stringer 210a, a second stringer 210b, and a third stringer 210c arranged in parallel between the engagement stringers 202a, 202b. As illustrated, the first stringer 210a, the second stringer 210b, and the third stringer 210c are to be engaged, respectively, via mechanical fasteners 240, to each of the engagement stringers 202a, 202b to form a frame. Moreover, a plurality of top slats 221, in particular, a first top slat 221a, a second top slat 221b, a third top slat 221c, a fourth top slat 221d, and a fifth top slat 221e (each having two legs 222 that are complementary to the slots 216 defined by each of the stringers 210), are to be fit into each corresponding slot 216 and placed on the first stringer 210a, the second stringer 210b, and the third stringer 210c.

Moreover, and with further specificity, each of the plurality of stringers 210a, 210b, 210c has a first end 211a, 211b, 211c and a second end 212a, 212b, 212c, and each first end 211a, 211b, 211c of the stringers 210a, 210b, 210c is to be engaged to the first engagement stringer 202a (via the mechanical fasteners 240a) and each second end 212a, 212b, 212c of the stringers 210a, 210b, 210c is to be engaged to the second engagement stringer 202b (via the mechanical fasteners 240b) to form the frame 201. Each of the plurality of stringers 202, 210 also are processed to include a first cut-out target 214a and a second target 214b each configured to receive an injection molded target insert 250a, 250b to reinforce the stringers 202, 210 and to facilitate lifting of the resulting pallet assembly 200 by forklift. Each of the plurality of stringers 210 also is processed to include a plurality of slots 216 (best seen in FIG. 4A) that allows the plurality of top slats 221 to mate with and be held by the frame 201 (via the mechanical fasteners 230, for example).

Returning generally to FIG. 1B, the first engagement stringer 202a and the second engagement stringer 202b serve to receive and hold the mechanical fasteners 240 for securably attaching each of the first stringer 210a, the second stringer 210b, and the third stringer 210c. Depending on the embodiment, each of the engagement stringers 202 and/or each of the stringers 210 include a screw boss(es) (best seen in FIG. 3) to receive the mechanical fasteners 230, 240 or any other mechanical fasteners (best seen in FIGS. 3 and 4A). Importantly, as illustrated in FIG. 1B, the mechanical fasteners 230, 240 may be driven into the screw boss(es) (the entire screw boss extending along the length, L, of the stringers 210) within each of the stringers 202, 210.

Referring now to FIG. 1C, a perspective view of an illustration of the example pallet assembly of FIG. 1B organized as a kit and ready to be shipped in a box is shown. In particular, in FIG. 1C, there is shown the multi-component, stringer type, two-way pallet assembly 200 of FIG. 1B. The engagement stringers 202 are arranged together, as are the stringers 210. The plurality of top slats 221 are stacked, and the injection molded target inserts 250 are together. Moreover, the mechanical fasteners 230, 240 are in a box. Together, all of the components are arranged such that they can be packed and shipped for fast and ready assembly.

Referring now to FIGS. 2A-2E, a side view of an illustration of an example engagement stringer, or of a stringer, of an example pallet assembly is shown in FIG. 2A; a side view of an illustration of an example slat of an example pallet assembly is shown in FIG. 2B; a side view of an illustration of another example engagement stringer, or of another example stringer, of an example pallet assembly is shown in FIG. 2C; a perspective view of an illustration of an example target insert of an example pallet assembly is shown in FIG. 2D; and a side view of a partial, exploded illustration of an example corner of an example frame of an example pallet assembly is shown in FIG. 2E, according to the present disclosure. In particular, FIG. 2A and FIG. 2C are each, respectively, a side view of an example first lineal engagement stringer 302a according to the present disclosure; however, each could be a side view of an example first lineal stringer 310a. Moreover, as illustrated, the side views of FIG. 2A and FIG. 2C are from the perspective of a first end 311a (opposite a second end 312a; not shown) of the first engagement stringer 302a. As such, in one aspect of the pallet assembly of the present disclosure, both the first engagement stringer 302a and the first stringer 310a have the same hollowed profile type as shown for 302a in FIG. 2A or 2C. In another aspect of the pallet assembly of the present disclosure, the first engagement stringer 302a may have a side view as shown in FIG. 2A, and the first stringer 310a may have a side view as shown in FIG. 2C, or vice versa.

More specifically, as shown in FIG. 2A, the first engagement stringer 302a has internal screw bosses 318a, 318b to receive mechanical fasteners (for example, for receiving a portion of the mechanical fasteners 340 as shown in FIG. 2E), and has an embedded multilayer composite strip 319a. Importantly, similar to the illustration of FIG. 2E, individual mechanical fasteners 340 may be driven through the screw bosses 318a, 318b of the first engagement stringer 302a, for example, into the screw bosses that are exposed at the ends of a first stringer 310a. In particular, as shown in FIG. 3, the individual mechanical fasteners may be driven at two pre-drilled points (best seen in FIG. 3) along the width, W, of the first engagement stringer 302a and through the internal screw bosses 318a, 318b (the screw bosses extending along the length, L, of the first engagement stringer 302a, for example). Moreover, the individual mechanical fasteners 340 may then continue to be driven (best seen in FIG. 3) through the embedded multilayer composite strip 319a of the first engagement stringer 302a and into the internal screw bosses of the first stringer 310a, etc.

As shown in FIG. 2B, a first top slat 321a has an embedded multilayer composite strip 319b. Importantly, similar to the illustration of FIG. 2E, individual mechanical fasteners may be driven through the embedded multilayer composite strip 319b of the first top slat 321a, for example, into the screw bosses of a first stringer 310a. In particular, as shown in FIG. 2E, the individual mechanical fastener(s) may be driven at two pre-drilled points (best seen in FIG. 2E; FIG. 3 shows one pre-drilled point for only one mechanical fastener 430) through the embedded multilayer composite strip 319b, and through an embedded multilayer composite strip and then into the internal screw bosses of the first stringer 310a. The top slat 321a may define a main wall and two legs 322 that are received by surface features or slots 316 defined on the given stringer.

As shown in FIG. 2C, in another aspect, the first engagement stringer 302a or the first stringer 310a has rounded internal screw bosses to receive mechanical fasteners (for example, for receiving a portion of the mechanical fasteners 340 as shown in FIG. 2E), and has an embedded multilayer composite strip 319a (right side) and any or all of embedded multilayer composite strips (e.g., top, left side, and/or bottom). Importantly, similar to the illustration of FIG. 2E, individual mechanical fasteners 340 may be driven through the rounded screw bosses 318a, 318b of the first engagement stringer 302a, for example, into the rounded (or non-rounded) screw bosses that are exposed at the ends of a first stringer 310a. In particular, as shown in FIG. 2E, the individual mechanical fasteners may be driven at two pre-drilled points along the width, W, of the first engagement stringer 302a and through the optional embedded multilayer composite strip and driven through the internal screw bosses 318a, 318b (the screw bosses extending along the length, L, of the first engagement stringer 302a, for example). Moreover, as shown in FIG. 2E, the individual mechanical fasteners 340 may then continue to be driven through the multilayer composite strip 319a of the first engagement stringer 302a and into the internal screw bosses of the first stringer 310a, etc.

In FIG. 2E, there is shown an example corner of an example frame of an example pallet assembly 300 having a first engagement stringer 302a, a first top slat 321a, a first stringer 310a, and mechanical fasteners. More specifically, as illustrated, the side view of FIG. 2E is from the perspective of a first end 311a (opposite a second end 312a; not shown) of the first engagement stringer 302a. The side view of FIG. 2E also shows an example of an injection molded target insert for a first target 314a at a first end 311a of the of the stringer 310a.

Even more specifically, as shown in FIG. 2A-2E in one aspect, the engagement stringers (e.g., stringer 302a) and the perpendicular stringers (e.g., stringer 310a) each have internal screw bosses 318a, 318b to receive mechanical fasteners (or a portion of the mechanical fasteners), and each have an embedded multilayer composite strip (e.g., embedded multilayer composite strip 319b) that lies parallel to the stacked screw bosses 318a, 318b of the pallet components, and optional embedded multilayer composite strip(s) on the top, bottom, and/or side(s), in order to provide increased strength and stiffness. Importantly, individual mechanical fasteners are driven through the screw bosses 318a, 318b of the engagement stringer 302a and, for example, into the screw bosses 318a, 318b that are exposed at the ends of the stringer 310a. Each of the composite strips (e.g., embedded multilayer composite strip 319b) operates as a stiffening layer for each of the lineal pallet components. Depending on the embodiment, each of the composite strips (e.g., embedded multilayer composite strip 319b) may have a first polymeric layer, a first mesh layer, wherein at least 20 percent of the first mesh layer is a void region, a composite layer of shredded fibrous material and polymeric material, and a second mesh layer, and a second polymeric layer; or may have a first polymeric layer with a layer height ranging from between about 0.23 mm to about 1.1 mm; a first mesh layer, wherein at least about 20.0 percent of the first mesh layer is a void region; a composite layer of shredded fibrous material and polymeric material, wherein the shredded fibrous material is of an average length between about 5.0 mm and about 50.0 mm, and the polymeric material has a granular size from between about 50.0 microns to about 2000.0 microns prior to heating; a second mesh layer, wherein at least about 20.0 percent of the second mesh layer is a void region; and a second polymeric layer with a layer height from between about 0.23 mm to about 1.1 mm; or may have a first polymeric layer with a layer height ranging from between about 0.23 mm to about 1.1 mm; a first mesh layer of fiberglass, wherein at least about 20.0 percent of the first mesh layer is a void region; a composite layer of shredded fibrous material and polymeric material, wherein the shredded fibrous material is of an average length between about 5.0 mm and about 50.0 mm, and the polymeric material has a granular size from between about 50.0 microns to 2000.0 microns prior to heating; a second mesh layer of fiberglass; and a second polymeric layer with a layer height from between about 0.23 mm to about 1.1 mm.

Referring now to FIG. 3, a perspective view of a partial illustration of an example pallet assembly according to the present disclosure is shown. In particular, in FIG. 3, there is shown a pallet assembly 400 having a first engagement stringer 402a, a second engagement stringer 402b (not shown), a first stringer 410a, a second stringer 410b (not shown), a third stringer 410c (not shown), a first top slat 421a, a second top slat 421b (not shown), a third top slat 421c (not shown), a fourth top slat 421d (not shown), a fifth top slat 421e (not shown), and mechanical fasteners 430, 440. As illustrated, the first engagement stringer 402a serves to receive and hold the mechanical fasteners 440 for securably attaching the first stringer 410a to the engagement stringer 402a. Each of the first engagement stringer 402a, the first stringer 410a, and the first top slat 421a include an embedded multilayer composite strip 419a in order to provide increased strength and stiffness. The first stringer 410a is processed to include surface features or slots 416 (best seen in FIG. 4A) to allow the first top slat 421a to mate with and be held by the frame 401. In particular, in FIG. 3, the first top slat 421a has two legs 422 that are complementary to the slots 416 defined by the first stringer 410a, and are fit into each corresponding slot 416. Mechanical fasteners 430 are driven through the first top slat 421a and into the first stringer 410a (into the internal screw boss; not shown) to provide additional engagement support between the first top slat 421a and the first stringer 410a.

Moreover, and with further specificity, the first end 411a of the first stringer 410a is to be engaged to the first engagement stringer 402a via the mechanical fasteners 440 to form a corner of a frame 401. As shown in FIG. 3, the first engagement stringer 402a has internal screw bosses 418a, 418b to receive a portion of the mechanical fasteners 440. Importantly, similar to the illustration of FIG. 1B, individual mechanical fasteners 440 are driven through the screw bosses 418a, 418b, respectively, of the first engagement stringer 402a into the screw bosses (not shown), respectively, of the first stringer 410a. In particular, in FIG. 3, the individual mechanical fasteners 440 are driven through two pre-drilled holes 417 defined by the first engagement stringer 402a and through the internal screw bosses 418a, 418b, through the embedded multilayer composite strip (e.g., embedded multilayer composite strip 319b) of the first engagement stringer 402a, and continue into the internal screw bosses of the first stringer 410a.

Referring now to FIG. 4A, a cross-sectional view of a partial exploded illustration of an example corner of an example frame of an example pallet assembly according to the present disclosure is shown. In particular, in FIG. 4A, there is shown a pallet assembly 500 having a first engagement stringer 502a, a second engagement stringer 502b (not shown), a first stringer 510a, a second stringer 510b (not shown), a third stringer 510c (not shown), a first top slat 521a, a second top slat 521b (not shown), a third top slat 521c (not shown), a fourth top slat 521d (not shown), a fifth top slat 521e (not shown), and mechanical fasteners 530, 540. As illustrated, the first engagement stringer 502a serves to receive and hold the mechanical fasteners 540 for securably attaching the first stringer 510a. Each of the first engagement stringer 502a, the first stringer 510a, and the first top slat 521a include an embedded multilayer composite strip 519b in order to provide increased strength and stiffness. The first stringer 510a is processed to include a first cut-out target 514a (shown) and a second target 514b (not shown). The first stringer 510a also is processed to include a plurality of slots 516 that allows the plurality of top slats (e.g., slat 521a) to mate with and be held by the frame.

In particular, in FIG. 4A, the first engagement stringer 502a has profile including an internal space 515 and a profile wall 513 at least partially defining the internal space 515. Moreover, the first stringer 510a has a first end 511a, a second end 512a (not shown), a top wall 509, a bottom wall 507, and internal screw bosses. Moreover, as illustrated, the first top slat 521a has two legs 522 that are complementary to the slots 516 defined by the top wall 509 of the first stringer 510a. Mechanical fastener 530a may be driven through the first top slat 521a, through the embedded multilayer composite strip 519b and through the embedded multilayer composite strip 519c into the internal screw boss to provide additional engagement support between the first top slat 521a and the first stringer 510a.

Moreover, and with further specificity, the first end 511a of the first stringer 510a is to be engaged to the first engagement stringer 502a via the mechanical fasteners 540 to form a corner of a frame. As shown in FIG. 4A, the first engagement stringer 502a has internal screw bosses 518a, 518b to receive a portion of the mechanical fasteners 540. Importantly, similar to the illustration of FIGS. 1B and 3, individual mechanical fasteners 540 are driven through the screw bosses 518a, 518b, respectively, of the first engagement stringer 502a into the screw bosses, respectively, of the first stringer 510a. In particular, in FIG. 4A, the individual mechanical fasteners 540 are driven through two pre-drilled holes 517 defined by the first engagement stringer 502a and through the internal screw bosses 518a, 518b, through the embedded multilayer composite strip 519a of the first engagement stringer 502a, and continue into the internal screw bosses 518a′, 518b′ of the first stringer 510a.

Furthermore, with further specificity, the first end 511a of the first stringer 510a is processed to include a first cut-out target 514a (shown) and a second target 514b (not shown). The bottom wall 507 of the first stringer 510a may be cut and processed to expose an opening to the internal space 515 and to remove a portion of the internal screw boss.

Referring now to FIG. 4B, a cross-sectional view of a partial illustration of an example corner of an example frame of an example pallet assembly according to the present disclosure is shown. In particular, in FIG. 4B, there is shown a pallet assembly 600 having a first engagement stringer 602a, a second engagement stringer 602b (not shown), a first stringer 610a, a second stringer 610b (not shown), a third stringer 610c (not shown), a first top slat 621a, a second top slat 621b (not shown), a third top slat 621c (not shown), a fourth top slat 621d (not shown), a fifth top slat 621e (not shown), and mechanical fasteners 630, 640. As illustrated, the first engagement stringer 602a receives and holds the mechanical fasteners 640 to securably attach the first stringer 610a. Each of the first engagement stringer 602a, the first stringer 610a, and the first top slat 521a include an embedded multilayer composite strip 619b. The first stringer 610a also is processed to include surface features or slots 616 and a first cut-out target 614a (shown) and a second target 614b (not shown).

In particular, in FIG. 4B, the first engagement stringer 602a has profile including an internal space 615 and a profile wall 613 at least partially defining the internal space 615. Moreover, the first stringer 610a has a first end 611a, a second end 612a (not shown), a top wall 609, a bottom wall 607, and internal screw bosses. Moreover, as illustrated, the first top slat 621a has a main wall and two legs 622 that are complementary to the slots 616 defined by the top wall 609 of the first stringer 610a. Mechanical fasteners 630 are driven through the first top slat 621a, through the embedded multilayer composite strip 619b and through the embedded multilayer composite strip 619c and into the internal screw boss to provide additional engagement support between the first top slat 621a and the first stringer 610a.

Moreover, and with further specificity, the first end 611a of the first stringer 610a is engaged to the first engagement stringer 602a via the mechanical fasteners 640 to form a corner of a frame. As shown in FIG. 4B, the first engagement stringer 602a has internal screw bosses 618a, 618b to receive a portion of the mechanical fasteners 640. Importantly, individual mechanical fasteners 640 are driven through the screw bosses 618a, 618b, respectively, of the first engagement stringer 602a into the screw bosses of the first stringer 610a. In particular, in FIG. 4B, the individual mechanical fasteners 640 are driven through two pre-drilled holes 617 defined by the first engagement stringer 602a and through the internal screw bosses 618a, 618b, through the embedded multilayer composite strip 619a of the first engagement stringer 602a, and into the internal screw bosses 618a′, 618b′ of the first stringer 610a.

FIGS. 5-14 are directed to a stackable pallet assembly. The stackable pallet assembly combines a pallet assembly of various embodiments discussed herein with additional components in order to provide a stackable pallet assembly. An example of multiple stackable pallet assemblies stacked upon one another is shown in FIG. 7. The stackable pallet assembly 550 discussed herein may use any of the various embodiments of the pallet assemblies discussed in reference to FIGS. 1A-4B. In various embodiments, the components of the stackable pallet assembly may be the same material as the pallet assemblies discussed in reference to FIGS. 1A-4B. Additionally or alternatively, one or more components may be made out of a different material than the pallet assembly (e.g., one or more component may be made out of steel). Example component material include synthetic material, steel, composite materials, plastic, wood, and/or the like.

Referring now to FIGS. 5 and 6, a stackable pallet assembly 550 is provided. FIG. 5 illustrates an exploded view of the stackable pallet assembly 550 and FIG. 6 illustrates an assembled view of the stackable pallet assembly 550. In various embodiments, a pallet assembly 100 may be equipped with stackable functionality. As shown, the stackable pallet assembly 550 may include a pallet assembly 100, one or more stackable inserts 555, one or more stackable extenders 560, and one or more stacking coupler 565. Each stackable insert 555 may be inserted into an end of the pallet assembly 100. For example, a stackable insert 555 may be inserted at each corner of the pallet assembly 100, as shown in FIG. 6. FIG. 7 illustrates multiple stackable pallet assemblies stacked on one another using the components of the stackable pallet assembly 550 discussed herein.

In various embodiments, the pallet assembly of the stackable pallet assembly 550 may be any of the embodiments discussed in reference to FIGS. 1A-4B. For example, while the pallet assembly of FIG. 5 is labelled as pallet assembly 100, other pallet assemblies, such as pallet assembly 200 of FIG. 1B, the pallet assembly 400 of FIG. 3, the pallet assembly 500 of FIG. 4A, or the pallet assembly 600 of FIG. 4B may be used with the additional components discussed herein to make up the stackable pallet assembly 550. Additionally or alternatively, the pallet assembly 100 may have a different structure than the pallet assembly 100 shown in FIGS. 1A-4B. Various embodiments of the stackable pallet assembly 550 may use any number of different pallet assembly designs that are structured to receive a stackable insert 555 discussed herein.

In various embodiments, each stackable insert 555 may be shaped to be received within an internal space (e.g., internal space 515 of FIG. 4A, internal space 615 of FIG. 4B, internal space 1115 of FIG. 11, etc.) of a pallet assembly. The internal space may be defined within an engagement stringer of the pallet assembly (as shown in FIGS. 2A, 2C, 4A, 4B, and 11). The internal space may define an insert aperture at each end of the stringer (e.g., an insert aperture is defined at each end of the internal space along the stringer). As such, a first engagement stringer (e.g., the first engagement stringer 102a of FIG. 1A) may define a first insert aperture 575a and a second insert aperture 575b, and a second engagement stringer (e.g., the second engagement stringer 102b) may define a third insert aperture 575c and a fourth insert aperture 575d. In various embodiments, as shown in FIG. 6, a stackable insert 555 may be inserted into each of the insert apertures. As such, a stackable insert 555 may be provided at each corner of the pallet assembly 100. For example, a first stackable insert may be inserted into a first insert aperture, a second stackable insert may be inserted into a second insert aperture, a third stackable insert may be inserted into a third insert aperture, and a fourth stackable insert may be inserted into a fourth insert aperture.

The stackable insert 555 may be held in place within the internal space via a friction fit. Additionally or alternatively, other attachment means, such as fasteners, may be used to secure the stackable insert 555. For example, a screw (e.g., the mechanical fasteners 440, such as screws shown in FIG. 3) may be used to secure the stackable insert 555. In such an instance, one or more screw apertures may be defined on the insert protrusion 800 to receive the mechanical fasteners 440 and secure the stackable insert 555. In various embodiments, the insert protrusion 800 may be sized to cause a holding force to be provided on the insert protrusion 800. For example, the rotational force caused by a pallet being placed on the stacking coupler 565 is countered by the contact between the insert protrusion 800 and the pallet assembly 100.

Referring now to FIGS. 8 and 9, a stackable insert 555 with a stackable extender 560 and stacking coupler 565 attached is shown. Collectively, the stackable insert 555, the stackable extender 560 and the stacking coupler 565 may be referred to as a stackable insert assembly. As shown, the stackable insert 555 includes an insert protrusion 800 that is insertable into the pallet assembly, as shown in FIG. 5. The stackable insert 555 also includes an extender aperture 805 in which the stackable extender 560 may be inserted. An additional view of the extender aperture 805 is shown in FIG. 14. The extender aperture 805 may extend along a first axis and the insert protrusion may extend along a second axis, wherein the first axis and the second axis are generally perpendicular. As such, the stackable extender(s) 560, upon placement into a given extender aperture 805, extend laterally from the pallet assembly 100.

In various embodiments, a stackable extender 560 and/or a stacking coupler 565 may be coupled to any stackable insert 555 discussed herein. For example, a first stackable extender may be attachable to the first stackable insert, a second stackable extender may be attachable to the second stackable insert, a third stackable extender may be attachable to the third stackable insert, and a fourth stackable extender may be attachable to the fourth stackable insert. Additionally, a first stacking coupler may be attachable to the first stackable extender, a second stacking coupler may be attachable to the second stackable extender, a third stacking coupler may be attachable to the third stackable extender, and a fourth stacking coupler may be attachable to the fourth stackable extender

In various embodiments, the insert protrusion 800 may be shaped to be received within an insert aperture (e.g., within the pallet assembly). As discussed above, an insert aperture may be defined as an end of an internal space (e.g., internal space 515 of FIG. 4A, internal space 615 of FIG. 4B, internal space 1115 of FIG. 11, etc.) of a pallet assembly. The internal space may be defined within an engagement stringer of the pallet assembly (as shown in FIGS. 2A, 2C, 4A, 4B, 5, and 11). The internal space may define an insert aperture at each end of the stringer (e.g., an insert aperture is defined at each end of the internal space along the stringer).

As discussed herein, such as in reference to FIGS. 2A and 2C, the internal spaces may define one or more screw bosses 318a, 318b. As such, the shape of the insert protrusion 800 may be based on the configuration of the screw boss within the internal space. As shown in FIGS. 11 and 12, the insert protrusion 800 may include one or more indentions 1200, 1205 that allow the insert protrusion 800 to fit within the internal space (e.g., internal space 1115 of FIG. 11). FIG. 10A illustrates a side view of the stackable insert 555 coupled with a stringer and FIG. 10B illustrates a side view of the stackable insert 555 detached from the stringer.

In various embodiments, the extender aperture 805 may be generally perpendicular to the insert protrusion 800, such that upon installation, the stackable extender(s) 560 are perpendicular to the top surface of the pallet assembly 100. The extender aperture 805 and the stackable extender 560 may have the same cross-sectional shape. For example, the cross-sectional shape may be circular, square, rectangle, and/or the like. As such, the extender aperture 805 may have a slightly larger cross-sectional area to allow the end of a stackable extender 560 to be inserted into the extender aperture 805. Example ends of a stackable extender 560 are shown in FIGS. 13A and 13B, and the end of the stackable extender 560 inserted into the extender aperture 805 is shown in FIG. 14. As shown in FIGS. 13A and 14, the stackable extender 560 may include one or more indentions 1300a, 1300b, 1305a, 1305b. The extender aperture 805 may include one or more protrusions to hold or otherwise support the stackable extender 560 that engages with one or more of the indentions 1300a, 1300b, 1305a, 1305b. Alternatively, as shown in FIG. 13B, the stackable extender 560 may not include any indentions (e.g., the edges of the stackable extender may form a cross-section shape, such as a square). In such an example, the cross-sectional shape of the stackable extender 560 may be the same as the cross-sectional shape of the extender aperture 805 (e.g., a square as shown in FIG. 13B, a rectangle, a circle, an oval, and/or the like).

The length of the stackable extender 560 may be changed and the stackable extenders shown in various figures are merely examples and not definitive as to the length of the stackable extenders 560. In various embodiments, the stackable extenders 560 may be adjustable (e.g., telescoping functionality that allows the stackable extender to be lengthened or shortened depending on the use case). For example, the height of an object to be loaded on the stackable pallet assembly 550 may determine the length of the stackable extenders 560. In such an example, the length of the stackable extenders 560 may be more than the height of object(s) on the stackable pallet assembly 550 to allow another stackable pallet assembly to be stacked on top of the given stackable pallet assembly (e.g., as shown in FIG. 7). Alternatively, the stackable extender(s) 560 may be a fixed length. In such an instance, the stackable extender(s) 560 may be replaced with other stackable extenders of different lengths (e.g., different stackable extender lengths may be used based on the use case of the stackable pallet assembly). In various embodiments, each of the stackable extenders 560 used for a given stackable pallet assembly 550 may be the same length to allow for another pallet to be level upon placement on top of the given stackable pallet assembly.

In various embodiments, a stacking coupler 565 may be attached to the stackable extender at the end opposite the stackable insert 555. The stacking coupler 565 may include a recess 810 to receive a footing 900 of a stackable insert 555. In such an instance, the recess 810 may be shaped as a female coupler and the footing 900 of the stackable insert 555 may be shaped as a male coupler. In an instance in which a stackable pallet assembly 550 is stacked on top of another stackable pallet assembly 550, as shown in FIG. 7, the footing 900 of the stackable insert 555 of the top stackable pallet assembly 550 may be received by the recess 810 of the stacking coupler 565 on the lower stackable pallet assembly 550.

In various embodiments, the stacking coupler 565 may be inserted into the stackable extender 560 (e.g., the coupler protrusion 905 shown in FIG. 9 may be inserted into the coupler aperture 1310 shown in FIGS. 13A and 13B). In such an example, the coupler protrusion 905 may be a male coupler and the coupler aperture 1310 may be a female coupler. Alternatively, the stacking coupler 565 may be unitary with the stackable extender 560 (e.g., the stacking coupler 565 and the stackable extender 560 may be a single component or otherwise permanently attached, such as via a weld).

The present disclosure may also include methods of manufacturing various embodiments of the stackable pallet assembly discussed herein. For example, the method may include providing a pallet assembly. The pallet assembly includes a plurality of insert apertures. The method may also include inserting a plurality of stackable inserts into the plurality of insert apertures of the pallet assembly. The method may further include attaching a plurality of stackable extenders to the plurality of stackable inserts. The method may still further include attaching a plurality of stacking coupler to the plurality of stackable extenders.

IV. Claim Clauses

Certain implementations of systems and methods consistent with the present disclosure are provided as follows:

Clause 1. A stackable pallet assembly comprising: a pallet assembly, wherein the pallet assembly comprises a plurality of insert apertures; a plurality of stackable inserts, wherein each of the plurality of stackable inserts is insertable into one of the plurality of insert apertures of the pallet assembly; a plurality of stackable extenders, wherein each of the plurality of stackable extenders is attachable to one of the plurality of stackable inserts; and a plurality of stacking coupler, wherein each of the plurality of stacking coupler is attachable to one of the plurality of stackable extenders.

Clause 2. The stackable pallet assembly of Clause 1, wherein the pallet assembly comprises a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture; wherein the plurality of stackable inserts comprises a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture; wherein the plurality of stackable extenders comprises a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; and wherein the plurality of stacking coupler comprises a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

Clause 3. The stackable pallet assembly of Clause 2, wherein the pallet assembly comprises a first engagement stringer and a second engagement stringer, wherein the first engagement stringer comprises the first insert aperture and the second insert aperture, and wherein the second engagement stringer comprises the third insert aperture and the fourth insert aperture.

Clause 4. The stackable pallet assembly of Clause 1, wherein each of the plurality of stackable inserts comprises an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

Clause 5. The stackable pallet assembly of Clause 4, wherein each of the plurality of stackable inserts comprise an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

Clause 6. The stackable pallet assembly of Clause 5, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the stackable inserts the one of the plurality of stackable extender extends perpendicular to the insert protrusion.

Clause 7. The stackable pallet assembly of Clause 1, wherein the pallet assembly defines a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile comprising an internal space and a profile wall at least partially defining the internal space.

Clause 8. The stackable pallet assembly of Clause 1, wherein each of the plurality of stackable extenders are attached to a corresponding stackable insert of the plurality of stackable inserts such that each of the plurality of stackable extenders extend laterally from the pallet assembly.

Clause 9. The stackable pallet assembly of Clause 1, wherein each of the plurality of stackable inserts comprise an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.

Clause 10. The stackable pallet assembly of Clause 1, wherein each of the plurality of stacking couplers are configured to receive a footing of an additional stackable insert.

Clause 11. The stackable pallet assembly of Clause 1, wherein each of the plurality of stackable inserts comprise a footing structured to fit into a stacking coupler of an additional stackable pallet assembly.

Clause 12. The stackable pallet assembly of Clause 1, wherein each of the plurality of stacking coupler comprise a coupler protrusion and each of the plurality of stackable extenders comprise a coupler aperture, wherein the coupler protrusion is structured to be inserted into the coupler aperture.

Clause 13. The stackable pallet assembly of Clause 2, wherein the first stacking coupler and the first stackable extender are unitary.

Clause 14. The stackable pallet assembly of Clause 1, wherein the pallet assembly comprises: (i) a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile comprising an internal space and a profile wall at least partially defining the internal space; (ii) a lineal stringer having a first end, a second end, a top wall, an internal screw boss, and an embedded lineal reinforcement, the top wall of the lineal stringer defining a plurality of slots; (iii) a lineal slat having a main wall, a leg, and an embedded lineal reinforcement, a portion of the leg configured to fit into a slot of the plurality of slots of the lineal stringer, a portion of the main wall configured to sit on a portion of the top wall when the leg is pressed into the slot of the lineal stringer; and (iv) a mechanical fastener for traversing the profile wall of the lineal engagement stringer and engaging with the internal screw boss of the lineal stringer, to securably fasten the first end of the lineal stringer to the lineal engagement stringer.

Clause 15. The stackable pallet assembly of Clause 14, wherein each slot of the plurality of slots of the lineal stringer corresponds to an individual lineal slat.

Clause 16. The stackable pallet assembly of Clause 14, wherein each pair of slots of the plurality of slots of the lineal stringer corresponds to an individual lineal slat.

Clause 17. The stackable pallet assembly of Clause 14, wherein the pallet assembly further comprises a second lineal engagement stringer and a second mechanical fastener for securably fastening the second end of the lineal stringer to the second lineal engagement stringer.

Clause 18. The stackable pallet assembly of Clause 14, wherein the pallet assembly further comprises a second lineal stringer and a third lineal stringer; wherein a second portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the second lineal stringer, a second portion of the main wall of the lineal slat configured to sit on a second portion of the top wall of the second lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer; and wherein a third portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the third lineal stringer, a third portion of the main wall configured to sit on a third portion of the top wall of the third lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer and the leg is pressed into the slot of the third lineal stringer.

Clause 19. The stackable pallet assembly of Clause 14, wherein the pallet assembly further comprising: a second lineal engagement stringer; a second lineal stringer and a third lineal stringer; a second mechanical fastener for securably fastening the second end of the lineal stringer to the second lineal engagement stringer; a third mechanical fastener for securably fastening the second end of the second lineal stringer to the second lineal engagement stringer; and a fourth mechanical fastener for securably fastening the second end of the third lineal stringer to the second lineal engagement stringer, wherein a second portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the second lineal stringer, a second portion of the main wall of the lineal slat configured to sit on a second portion of the top wall of the second lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer, and wherein a third portion of the leg of the lineal slat is configured to fit into a slot of a plurality of slots of the third lineal stringer, a third portion of the main wall configured to sit on a third portion of the top wall of the third lineal stringer when the leg is pressed into the slot of the lineal stringer and the leg is pressed into the slot of the second lineal stringer and the leg is pressed into the slot of the third lineal stringer.

Clause 20. The stackable pallet assembly of Clause 19, wherein the lineal engagement stringer and the second lineal engagement stringer sandwich the lineal stringer, the second lineal stringer, and the third lineal stringer.

Clause 21. The stackable pallet assembly of Clause 19, wherein the pallet assembly further comprises a plurality of mechanical fasteners for traversing the main wall of the lineal slat and engaging with the internal screw boss of the lineal stringer, to securably fasten the lineal slat to the lineal stringer.

Clause 22. The stackable pallet assembly of Clause 19, wherein the profile of the lineal engagement stringer further comprises a multilayer composite strip orientated parallel to the profile wall as the embedded lineal reinforcement.

Clause 23. The stackable pallet assembly of Clause 19, wherein the lineal stringer further comprises a multilayer composite strip orientated parallel to the top wall as the embedded lineal reinforcement.

Clause 24. The stackable pallet assembly of Clause 23, wherein the lineal slat further comprises a multilayer composite strip orientated parallel to the main wall as the embedded lineal reinforcement.

Clause 25. A method of manufacturing a stackable pallet assembly comprising: providing a pallet assembly, wherein the pallet assembly comprises a plurality of insert apertures; inserting a plurality of stackable inserts into the plurality of insert apertures of the pallet assembly; attaching a plurality of stackable extenders to the plurality of stackable inserts; and attaching a plurality of stacking coupler to the plurality of stackable extenders.

Clause 26. The method of Clause 25, wherein the pallet assembly comprises a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture; wherein the plurality of stackable inserts comprises a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture; wherein the plurality of stackable extenders comprises a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; and wherein the plurality of stacking coupler comprises a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

Clause 27. The method of Clause 26, wherein the pallet assembly comprises a first engagement stringer and a second engagement stringer, wherein the first engagement stringer comprises the first insert aperture and the second insert aperture, and wherein the second engagement stringer comprises the third insert aperture and the fourth insert aperture.

Clause 28. The method of Clause 25, wherein each of the plurality of stackable inserts comprises an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

Clause 29. The method of Clause 28, wherein each of the plurality of stackable inserts comprise an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

Clause 30. The method of Clause 29, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the plurality of stackable inserts, the one of the plurality of stackable extenders extends perpendicular to the insert protrusion.

Clause 31. The method of Clause 25, wherein the pallet assembly defines a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile comprising an internal space and a profile wall at least partially defining the internal space.

Clause 32. The method of Clause 25, wherein each of the plurality of stackable extenders are attached to a corresponding stackable insert of the plurality of stackable inserts such that each of the plurality of stackable extenders extend laterally from the pallet assembly.

Clause 33. The method of Clause 25, wherein each of the plurality of stackable inserts comprise an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.

Clause 34. The method of Clause 25, wherein each of the plurality of stacking couplers are configured to receive a footing of an additional stackable insert.

Clause 35. The method of Clause 25, wherein each of the plurality of stackable inserts comprise a footing structured to fit into a stacking coupler of an additional stackable pallet assembly.

Clause 36. The method of Clause 25, wherein each of the plurality of stacking coupler comprise a coupler protrusion and each of the plurality of stackable extenders comprise a coupler aperture, wherein the coupler protrusion is structured to be inserted into the coupler aperture.

Clause 37. The method of Clause 26, wherein the first stacking coupler and the first stackable extender are unitary.

It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A stackable pallet assembly comprising: a pallet assembly, wherein the pallet assembly comprises a plurality of insert apertures;a plurality of stackable inserts, wherein each of the plurality of stackable inserts is insertable into one of the plurality of insert apertures of the pallet assembly;a plurality of stackable extenders, wherein each of the plurality of stackable extenders is attachable to one of the plurality of stackable inserts; anda plurality of stacking coupler, wherein each of the plurality of stacking coupler is attachable to one of the plurality of stackable extenders.

2. The stackable pallet assembly of claim 1, wherein the pallet assembly comprises a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture;wherein the plurality of stackable inserts comprises a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture;wherein the plurality of stackable extenders comprises a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; andwherein the plurality of stacking coupler comprises a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

3. The stackable pallet assembly of claim 2, wherein the pallet assembly comprises a first engagement stringer and a second engagement stringer, wherein the first engagement stringer comprises the first insert aperture and the second insert aperture, and wherein the second engagement stringer comprises the third insert aperture and the fourth insert aperture.

4. The stackable pallet assembly of claim 1, wherein each of the plurality of stackable inserts comprises an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

5. The stackable pallet assembly of claim 4, wherein each of the plurality of stackable inserts comprise an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

6. The stackable pallet assembly of claim 5, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the plurality of stackable inserts, the one of the plurality of stackable extenders extends perpendicular to the insert protrusion.

7. The stackable pallet assembly of claim 1, wherein the pallet assembly defines a lineal engagement stringer having a profile and an embedded lineal reinforcement, the profile comprising an internal space and a profile wall at least partially defining the internal space.

8. The stackable pallet assembly of claim 1, wherein each of the plurality of stackable extenders are attached to a corresponding stackable insert of the plurality of stackable inserts such that each of the plurality of stackable extenders extend laterally from the pallet assembly.

9. The stackable pallet assembly of claim 1, wherein each of the plurality of stackable inserts comprise an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.

10. The stackable pallet assembly of claim 1, wherein each of the plurality of stacking couplers are configured to receive a footing of an additional stackable insert.

11. The stackable pallet assembly of claim 1, wherein each of the plurality of stackable inserts comprise a footing structured to fit into a stacking coupler of an additional stackable pallet assembly.

12. The stackable pallet assembly of claim 1, wherein each of the plurality of stacking coupler comprise a coupler protrusion and each of the plurality of stackable extenders comprise a coupler aperture, wherein the coupler protrusion is structured to be inserted into the coupler aperture.

13. The stackable pallet assembly of claim 2, wherein the first stacking coupler and the first stackable extender are unitary.

14. A method of manufacturing a stackable pallet assembly comprising: providing a pallet assembly, wherein the pallet assembly comprises a plurality of insert apertures;inserting a plurality of stackable inserts into the plurality of insert apertures of the pallet assembly;attaching a plurality of stackable extenders to the plurality of stackable inserts; andattaching a plurality of stacking coupler to the plurality of stackable extenders.

15. The method of claim 14, wherein the pallet assembly comprises a first insert aperture, a second insert aperture, a third insert aperture, and a fourth insert aperture;wherein the plurality of stackable inserts comprises a first stackable insert that is insertable into the first insert aperture, a second stackable insert that is insertable into the second insert aperture, a third stackable insert that is insertable into the third insert aperture, and a fourth stackable insert that is insertable into the fourth insert aperture;wherein the plurality of stackable extenders comprises a first stackable extender that is attachable to the first stackable insert, a second stackable extender that is attachable to the second stackable insert, a third stackable extender that is attachable to the third stackable insert, and a fourth stackable extender that is attachable to the fourth stackable insert; andwherein the plurality of stacking coupler comprises a first stacking coupler that is attachable to the first stackable extender, a second stacking coupler that is attachable to the second stackable extender, a third stacking coupler that is attachable to the third stackable extender, and a fourth stacking coupler that is attachable to the fourth stackable extender.

16. The method of claim 15, wherein the pallet assembly comprises a first engagement stringer and a second engagement stringer, wherein the first engagement stringer comprises the first insert aperture and the second insert aperture, and wherein the second engagement stringer comprises the third insert aperture and the fourth insert aperture.

17. The method of claim 14, wherein each of the plurality of stackable inserts comprises an insert protrusion, wherein the insert protrusion is structured to fit within one of the plurality of insert apertures.

18. The method of claim 17, wherein each of the plurality of stackable inserts comprise an extender aperture, wherein the extender aperture of each of the plurality of stackable inserts is structured to receive one of the plurality of stackable extenders.

19. The method of claim 18, wherein the extender aperture is perpendicular to the insert protrusion, wherein upon attachment of one of the plurality of stackable extenders to one of the plurality of stackable inserts, the one of the plurality of stackable extenders extends perpendicular to the insert protrusion.

20. The method of claim 15, wherein each of the plurality of stackable inserts comprise an insert protrusion, wherein the insert protrusion is insertable into one of the plurality of insert apertures.