A system and method are provided for manufacturing a plastic pallet having a plurality of runner assemblies with embedded support structures. Each runner assembly may include a top runner board, a bottom runner board, and a plurality of support structures embedded into the top and bottom runner boards. The pallet may be manufactured using heat to at least partially penetrate and soften the runner boards, to soften the support structures, and to weld the support structures to the runner boards in an embedded manner.

In one embodiment, a maintainable pallet is provided with interchangeable support structures and sensors for identifying any damage that the interchangeable support structures may experience. The maintainable pallet may include two side supports, two end supports coupled to the two side supports end-to-end to form a rectangle, a central support position between the two side supports, a plurality of top transverse support fastened onto the two side supports to form a top loading surface and the central support with two-part releasable fasteners, and two bottom transverse supports fastened to the ends of the two side supports to form a bottom surface with two-part releasable fasteners. Sensors, in some embodiments, may be embedded in the two side supports to measure, for example, acceleration, location, or other logistic information. When a damaged piece is identified, the maintainable pallet can be disassembled by unfastening the two-part releasable fasteners to remove the damaged piece; and a new interchangeable piece will replace the damaged piece.

A modular pallet formed from a plurality of frame members and a plurality of deck members. The deck members extend between the frame members to define an upper deck surface and optionally a lower deck surface of the pallet. A plurality of spaced-apart channels are formed in at least an upper surface of the frame members to receive the deck members. In some embodiments the pallet may be configured as a stringer pallet and in other embodiments the pallet may be configured as a block pallet. In some embodiments the frame members are unitary stringers. In other embodiments the frame members are modular structures each comprising a block pallet subassembly and a deck support panel. The number, size, orientation and spacing of the channels formed in the frame members and the corresponding arrangement of the deck members may vary in different embodiments of the pallet. Once assembled, the frame members and deck members may be integrally connected, such as by heat welding. In some embodiments the pallet is formed from readily recyclable plastic.

Composite pallets and methods for making and using composite pallets are disclosed. An example composite pallet may include a plurality of base boards. The base boards may include a first resin material and a first fiber material. A plurality of support blocks may be coupled to the base boards. The support blocks may include a second resin material and an impact modifier. A plurality of intermediate boards may be coupled to the support blocks. The intermediate boards may include a third resin material and a second fiber material. One or more top end boards may be coupled to the intermediate boards. The one or more top end boards may include a fourth resin material and a third fiber material. One or more top boards may be disposed adjacent to at least one of the one or more top end boards. The one or more top boards may include a fifth resin material.

A pallet comprising upper and lower platforms connected by a plurality of blocks. The upper platform includes a plurality of upper platform pedestals and the lower platform includes a plurality of lower platform pedestals. The lower platform pedestals are aligned with the upper platform pedestals such that the lower platform pedestals and the upper platform pedestals extend towards one another. The plurality of blocks interlockingly engage with and extend between the upper and lower platform pedestals to connect the upper and lower platforms. Each block includes an upper recess and a lower recess. The upper recess matches the shape of and receives one of the upper platform pedestals. The lower recess matches the shape of and receives one of the lower platform pedestals. The upper platform, the lower platform, and the plurality of blocks are made of a polymeric material.

A composite pallet for the transport and long-term storage of barrels, comprising a base element made of plastic with a top side, an under side and support projections; a deck element made of plastic with a top side for storing the barrels; and a depositing area for holding a vertical barrel. The deck element has an under side and support projections resting on the base element support projections, and is supported against the base element; the deck element under side is at a distance from the base element top side. Support inserts made of a material with a creep modulus which is higher over a predefined period than a creep modulus of plastic, and the decrease in which is lower than that of plastic over the specified period, are locked into holders on the deck element under side and on the base element top side.

A pallet comprising upper and lower platforms connected by a plurality of blocks. The upper platform includes a plurality of upper platform pedestals and the lower platform includes a plurality of lower platform pedestals. The lower platform pedestals are aligned with the upper platform pedestals such that the lower platform pedestals and the upper platform pedestals extend towards one another. The plurality of blocks interlockingly engage with and extend between the upper and lower platform pedestals to connect the upper and lower platforms. Each block includes an upper recess and a lower recess. The upper recess matches the shape of and receives one of the upper platform pedestals. The lower recess matches the shape of and receives one of the lower platform pedestals. The upper platform, the lower platform, and the plurality of blocks are made of a polymeric material.

A modular pallet formed from a plurality of frame members and a plurality of deck members. The deck members extend between the frame members to define an upper deck surface and optionally a lower deck surface of the pallet. A plurality of spaced-apart channels are formed in at least an upper surface of the frame members to receive the deck members. In some embodiments the pallet may be configured as a stringer pallet and in other embodiments the pallet may be configured as a block pallet. In some embodiments the frame members are unitary stringers. In other embodiments the frame members are modular structures each comprising a block pallet subassembly and a deck support panel. The number, size, orientation and spacing of the channels formed in the frame members and the corresponding arrangement of the deck members may vary in different embodiments of the pallet. Once assembled, the frame members and deck members may be integrally connected, such as by heat welding. In some embodiments the pallet is formed from readily recyclable plastic.

A plastic composite modular rebuildable pallet has replaceable top boards, stringers and bottom boards made from a thermoplastic resin with variable amounts of long glass fiber reinforcements molded into the pallet boards. The top boards have on center circular indexing buttons. The stringers have top lengthwise molded in channels for receiving multiple reinforcing metal bars, rods or tubes held in place by the top boards. The bottom boards have two circular cups at each end on their bottom surfaces for indexing with the on center buttons of the below pallet when the empty pallets are stacked for storage and transportation. This arrangement allows for the bottom boards to be horizontally reversibly mounted on the bottom surface of the stringers in either 180? horizontal direction. The bottom boards have thick bottom feet pads with foot wear-resistant pads for sliding engagement with ground surfaces.

In one embodiment, a maintainable pallet is provided with interchangeable support structures and sensors for identifying any damage that the interchangeable support structures may experience. The maintainable pallet may include two side supports, two end supports coupled to the two side supports end-to-end to form a rectangle, a central support position between the two side supports, a plurality of top transverse support fastened onto the two side supports to form a top loading surface and the central support with two-part releasable fasteners, and two bottom transverse supports fastened to the ends of the two side supports to form a bottom surface with two-part releasable fasteners. Sensors, in some embodiments, may be embedded in the two side supports to measure, for example, acceleration, location, or other logistic information. When a damaged piece is identified, the maintainable pallet can be disassembled by unfastening the two-part releasable fasteners to remove the damaged piece; and a new interchangeable piece will replace the damaged piece.