CA2598674A1

CA2598674A1 - Skeleton pallets with optional faceboards

Info

Publication number: CA2598674A1
Application number: CA002598674A
Authority: CA
Inventors: Stewart Ferguson
Original assignee: Individual
Current assignee: Individual
Priority date: 2006-08-25
Filing date: 2007-08-23
Publication date: 2008-02-25
Also published as: US20080047473A1

Abstract

A pallet is created from two sets of thin stringers crossing and mated orthogonally, forming forkway notches and including ribs to guide the fingers of lifting machinery through the pallet. The pallet may include an optional mortised deck.

Description

SKELETON PALLETS WITH OPTIONAL FACEBOARDS
TECHNICAL FIELD
The technical field generally relates to portable platforms. More specifically, the technical field relates to a pallet for handling, storing, or moving materials and packages manipulable with a lifting machine.
BACKGROUND
Pallets, sometimes colloquially referred to as "skids," were slowly introduced during the 20th century in order to facilitate the transportation of goods.
Before the introduction of pallets, goods to be shipped were placed in boxes, crates, or barrels.
These containers had to be loaded or unloaded from the shipping vehicle by hand one at a time, a very time-consuming and dangerous process. Now, materials can be combined together with straps, shrink wrap, or some other means into a unit load, placed on a pallet, and then manipulated as a unit with a wide variety of lifting machines, such as forklifts or hand trucks. Pallets thus allow materials to be transported much more safely and efficiently than before. The usefulness of pallets is shown by their ubiquity:
around five hundred million pallets are constructed in the United States each year, and aimost two billion pallets are in use in the United States at any time.

Pallets are commonly constructed from a variety of materials, including plastic, corrugated fiber, and steel. The most often used material for constructing a pallet is wood: over 90 percent of the pallets in use are so constructed. The materials handling industry is one of the largest domestic consumers of wood fiber and timber, consuming more timber (approximately 70 million tons) per year than the paper, home construction, or home repair industries. Pallets come in a variety of designs in order to meet the demands of the particular application for which they are intended. For instance, a pallet FRGS\27712AP.D0C -1 -destined to carry a particularly heavy load would need to be particularly strong, a pallet destined to carry a load on an airplane would need to be particularly light and a pallet destined to be produced in large quantities would need to be particularly inexpensive and recyclable. Thus, the choice of design and building material will often depend on the intended application.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. In accordance with this invention, several forms of the invention including a pallet, a deck, and a method for construction are provided.

The pallet form of the invention comprises a set of lower stringers that are spaced apart. Each lower stringer includes a set of outer slots, a set of inner slots, and a set of projections. Each projection is situated at either a distal end or a proximal end of a lower stringer. Each outer slot is adjacent to a projection, each inner slot being adjacent to an outer slot. The pallet also comprises a set of upper stringers that are spaced apart. Each upper stringer includes a set of outer slots, a set of inner slots, a set of rib slots, a set of notches, and a set of projections. Each projection being situated at either a distal end or a proximal end of an upper stringer. Each outer slot is adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end. Each rib slot is situated at approximately the center of each notch. The pallet further comprises a set of ribs that sit into the set of rib slots of the upper stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load. The sets of outer slots engage one another and the set of inner slots engage one another to form forkways by the set of notches. From the set of rib slots, the set of ribs protrude into the forkways to guide fingers of lifting machinery so the pallet may be possessed.

In accordance with further aspects of this invention, a pallet that includes a deck is provided. The pallet comprises a set of lower stringers that are spaced apart.
Each lower stringer includes a set of outer slots, a set of inner slots, and a set of projections. Each projection is situated at either a distal end or a proximal end of a lower stringer. Each FRGS\27712AP.DOC -2-outer slot is adjacent to a projection, each inner slot being adjacent to the outer slot. The pallet further comprises a set of upper stringers that are spaced apart. Each upper stringer includes a set of outer slots, a set of inner slots, a set of notches, and a set of projections.
Each projection is situated at either a distal end or a proximal end of an upper stringer.
Each outer slot is adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end. The pallet also includes a deck which bottom is cut to form a set of mortises. A first subset of the mortises is spaced apart and a second subset of the mortises being spaced apart and orthogonal to the first subset of the mortises, the set of mortises receiving a structure created when the sets of upper stringers and lower stringers are orthogonally mated so as to reduce racking.
In accordance with further aspects of this invention, a method form of the invention includes a method for manufacturing a pallet is provided. The method includes obtaining lumber of approximate four-inch height and appropriate width and length;
configuring the teeth of a saw to cut notches and slots in the lumber; using the saw to cut the notches and slots in the lumber in appropriate locations for a set of upper stringers;
using the same saw to cut similar notches and slots in the lumber in appropriate locations for a set of lower stringers; using a different saw to divide the notched lumber lengthwise into pieces of approximate four-inch height and. approximate one-half-inch width;
arranging the upper stringers and lower stringers orthogonally in an interlocking manner;
creating a set of ribs; and attaching the set of ribs.

DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

FIGURE 1 is a perspective view of one embodiment of the present invention;
FIGURE 2 is a top view of one embodiment of the present invention;
FIGURE 3 is a side elevation of one embodiment of the present invention;
FIGURE 4 is a front elevation of one embodiment of the present invention;
FIGURES 5A and 5B are elevation views of an upper stringer and a lower stringer used in one embodiment of the present invention;

FRGS\27712AP.DOC -3-FIGURE 6 is a detail perspective view of one embodiment of the present invention;
FIGURE 7 is an elevation view of a lower stringer used in one embodiment of the present invention;
FIGURE 8 is a perspective view of a piece of lumber used in the construction of one embodiment of the present invention.
FIGURE 9 is a perspective view of one embodiment of the present invention, with the optional deck installed;
FIGURE 10 is an exploded perspective view of one embodiment of the present invention, with the optional deck;
FIGURE 11 is a front elevation of one embodiment of the optional deck of the present invention;
FIGURE 12 is a side elevation of one embodiment of the optional deck of the present invention;
FIGURE 13 is a perspective view of the underside of one embodiment of the optional deck of the present invention;
FIGURE 14 is a perspective view illustrating the installation of a repair stringer in one embodiment of the present invention.
FIGURES 15A-15F are process diagrams describing an exemplary method for manufacturing pallets.
FIGURE 16 is a process diagram describing an exemplary method for repairing pallets.
DETAILED DESCRIPTION
Several issues arise in the construction of pallets. The first issue concerns the particular characteristics of the lumber chosen as construction material.
Certain types of lumber are more economical to manufacture or purchase on the open market than others.
However, less expensive lumber is often more difficult to form into a pallet of the necessary dimensions or strength for a given application. The second issue is that of recyclability. A wooden pallet will better resist racking, the torsional displacement of the pallet structure, by nailing the components together. However, the presence of nails makes the pallet less amenable to simple recycling techniques. The third issue is that of maneuverability. Many wooden pallet designs are "two-way," which allow the fingers of FRGS\27712AP.DOC -4-a forklift or other lifting machinery to enter the pallet from only one direction. Some other designs are "four-way," which allow the fingers to enter the pallet from any side, but some of those designs require the fmgers to be set to different widths in order to enter a different side. Yet another issue is that of repairability. The fingers often wound the structural members of the pallet, contacting them in unintended ways and causing damage. Not all pallet designs allow for the pallet to be easily repaired, and instead they must be discarded when any piece of the structure is damaged. Various embodiments of the present invention focus on a pallet constructed out of thin, mutually notched stringers;
an optional deck to provide structural support and load distribution; and methods for construction and repair of the pallet.
FIG. 1 shows a perspective view of one embodiment of the present invention. It is understood that the pallet as described by various embodiments of the invention is not limited to particular dimensions, and any suitable size will do. One suitable size includes 48 inches by 40 inches. The pallet is composed of two sets of orthogonally crossing stringers. Such sets of stringers are composed of a set of substantially similar lower stringers 1 a-1 e and a set of substantially similar upper stringers 2a-2e.
The set of lower stringers 1 a-1 e includes a pair of outer lower stringers 1 a, 1 e; a pair of inner lower stringers 1 b, 1 d; and preferably one but possibly a different number of central lower stringers 1 c. The set of upper stringers 2a-2e includes a pair of outer upper stringers 2a, 2e; a pair of inner upper stringers 2b, 2d; and preferably one but possibly a different number of central upper stringers 2c.
The lower stringers 1 a- l e have notches 3 that allow the fingers of a forklift or other lifting machinery to pass through the pallet. The upper stringers 2a-2e also contain notches 7 that allow the fingers of a forklift or other lifting machinery to pass through the pallet.
The lower stringers 1 a-1 e and upper stringers 2a-2e fit together such that the ends of the lower stringers create projections 4 that extend past the outer upper stringers 2a, 2e so as to laterally guide the fingers of a forklift or other lifting machinery through the pallet, and such that the ends of the upper stringers 2a-2e create projections 8 that extend past the outer lower stringers 1 a, 1 e so as to laterally guide the fingers of a forklift or other lifting machinery through the pallet. Notably, the notches 7 in the upper stringers 2a-2e further have slots 13, as visible in FIG. 5A, in which are fastened guide ribs 6 with FRGS127712AP.DOC -5-beveled ends 25. One embodiment of the beveled ends 25 of a guide rib 21 is depicted in more detail in FIG. 6. The guide ribs 6 extend past the outer upper stringers 2a, 2e to vertically guide the fingers of a forklift or other lifting machinery through the pallet so as to reduce damage to the pallet.
The intersections of each lower stringer l a- l e with each upper stringer 2a-2e are preferably cut into slots 9, 10, 11, and 12, as visible in FIGS. 5A and 5B, so that each joint fits together snugly and the pallet is of the minimum possible height.
In one embodiment, the tops of the lower stringers 1 a-1 e and the upper stringers 2a-2e are flush with one another. In other embodiments, they are not flush.
FIG. 2 shows a top view of one embodiment of the present invention. This view shows the orthogonal relationship between the lower stringers 1 a-1 e and the upper stringers 2a-2e, and gives a clearer depiction of where the fingers P, P' of the forklift or other lifting machinery pass through the pallet. This figure also shows the preferable embodiment of the guide ribs 6 as extending past the outer upper stringers 2a, 2e and extending the entire width of the pallet as one continuous piece to reduce damage to any of the upper stringers 2a-2e.
FIG. 3 shows a side elevation of one embodiment of the present invention. The load L is pictured in broken outline sitting on top of the pallet. The guide ribs 6 are shown in their slots 13, which slots 13 are preferably deep enough so that the guide ribs 6 protrude a suitable distance, such as approximately one-sixteenth of an inch past the rest of the notch 7, and vertically guide the fmgers P of a forklift or other lifting machinery beneath the upper stringers 2a-2e to reduce damage. The side elevation as illustrated by FIG. 3 also shows the projections 4 guiding the fingers P of a forklift or other lifting mechanism horizontally below the guide ribs 6 and along the lower stringers 1 a-1 e of the pallet. FIG. 3 further shows the location of one central lower stringer Ic, situated between the two inner lower stringers 1 b, 1 d.
FIG. 4 shows a front elevation of one embodiment of the present invention. The load L is pictured in broken outline sitting on top of the pallet. The projections 8 are pictured guiding the fingers P' of a forklift or other lifting machinery horizontally through the notches 3. The fingers P' of a forklift or other lifting machinery would pass through above the notches 3 to possess the load L, lifting the load L and the pallet as secured by FRGS~27712AP.AOC -6-strap S. The front elevation as illustrated by FIG. 4 also shows one central upper stringer 2c, situated between the two inner upper stringers 2b, 2d.
FIG. 5A shows an elevation view of one embodiment of an upper stringer 2a-2e.
Upper stringer 2a-2e has two notches 7 at either end, far enough from each end of the upper stringer 2a-2e to leave projections 8. Each of these notches 7 has an outer slot 11 and an inner slot 12, each of which is of such a width as to snugly fit the width of a lower stringer 1 a-1 e within it. Once assembled, the remaining space in the notches 7 is at least wide enough to admit the fingers of a forklift or other lifting machinery beneath it. Upper stringer 2a-2e further has a set of slots 20, each of which is also of such a width as to snugly fit the width of a lower stringer l a- I e within it. In one embodiment, each of the slots 11, 12, and 20 extends to a depth of approximately half the height of the upper stringer 2a-2e so that when orthogonally mated with the lower stringers l a- l e, the upper stringers 2a-2e and lower stringers la-Ie join to form a structure with a flush top. Each of the notches 7 has an additional slot 13 preferably located at its midpoint.
These slots 13 are deep enough so that the guide rib 6 (omitted in this figure, but visible in FIG. 3), when seated in the slot 13, protrudes about one-sixteenth of an inch from the rest of the notch 7; and are wide enough so that the guide rib 6 fits snugly within the slot 13. The rest of the notch 7 is cut to a depth of less than half of the height of the upper stringer 2a-2e, so that when the upper stringers 2a-2e and lower stringers 1 a-1 e are orthogonally mated, the lower stringers 1 a-1 e are held in securely by both edges of the slots 9 and 10 but the fingers of the forklift or other lifting machinery can still pass through under the notches 7 and guide ribs 6. All of the upper stringers 2a-2e are preferably of substantially the same shape. This way, if one upper stringer 2a-2e is damaged, it can be replaced by an extra upper stringer 2a-2e or repaired by fastening a repair stringer 5 next to the damaged stringer, as shown shaded in FIG. 1 and further described below.
FIG. 5B shows an elevation view of one embodiment of a lower stringer l a-1 e.
Lower stringer 1 a-1 e has two notches 3 at either end, far enough from each end of the lower stringer la-le to leave projections 4. Each of these notches 3 has an outer slot 9 and an inner slot 10, each of which is of such a width as to snugly fit the width of an upper stringer 2a-2e within it. Once assembled, the remaining space in the notch 3 is at least wide enough to admit the fingers of a forklift or other lifting machinery above it and beneath the top surface of the pallet. Lower stringer l a- l e further has a set of slots 19, FRGS\27712AP.DOC -7-each of which is also of such a width as to snugly fit the width of an upper stringer 2a-2e within it. In one embodiments, each of the slots 9, 10, and 19 extends to a depth of approximately half the height of the lower stringer 1 a-1 e so that when orthogonally mated with the upper stringer 2a-2e, the upper stringers 2a-2e and the lower stringers la-le join to form a structure with a flush top. The rest of the notch 3 is cut to a depth of less than half of the height of the lower stringer 1 a-1 e, so that the upper stringers 2a-2e are held in securely by both edges of the slots 9 and 10 but the fingers of a forklift or other lifting machinery can still pass through above the notches 3 above it and beneath the top surface of the pallet. All of the lower stringers 1 a- l e are preferably of substantially the same shape. This way, if a lower stringer 1 a-1 e is damaged, it can be replaced by an extra lower stringer l a-1 e or repaired by fastening an repair stringer 5 next to the damaged lower stringer 1 a- I e as shown shaded in FIG. 1 with regard to a damaged upper stringer 2a-2e and described further below.
FIGS. 5A and 5B also show that one embodiment of the lower notches 7, the upper notches 3, and the slots 9, 10, 11, 12, 19, and 20 may have approximately similar dimensions on both the lower stringers l a-1 e and the upper stringers 2a-2e.
In such an embodiment where the dimensions of the notches and slots are similar, the same tool may be used to remove material from a piece of lumber to create both the lower stringers 1 a-1 e and the upper stringers 2a-2e. This may make the construction of a pallet efficient and cost effective. Additionally, the paths created for the fingers of the forklift or other lifting machinery by the lower notches 7 and the upper notches 3 will be spaced the same distance apart. This may be beneficial because the same lifting machinery may be used to lift a pallet from either direction without having to reset the width of the fingers, thus improving the efficiency of use of the pallet.
Some embodiments of the pallet may be flipped over, such that the notches 7 and guide ribs 6 in the upper stringers 2a-2e as visible in FIG. 1 are facing the load instead of facing away from the load. In another embodiment, the pallet contains additional guide ribs orthogonal to the guide ribs described above, and located within additional slots cut into the notches in the lower stringers so as to vertically guide the fingers of a forklift or other lifting mechanism over the lower stringers. FIG. 6 illustrates one such embodiment, in which the guide ribs 6 attached to the upper stringers 2a-2e and the guide ribs 21 attached to the lower stringers la-le are mortised at their intersection 22.
These FRGS\27712AP.DOC -8-embodiments are not depicted in full, but their creation would be readily apparent to those skilled in the art.
FIG. 7 shows a lower stringer 24a-e of one embodiment of the pallet in which all of the notches 7, 23 open away from the load. This lower stringer 24a-e is similar to the lower stringer la-le depicted in FIG. 5B, and interlocks with the upper stringers 2a-2e, albeit in a different manner as depicted in FIG. 1. Since the notches 23 are located on the edge opposing the outer slots 9, the inner slots 10, and the center slots 19, the forkways formed by the notches 23 will open away from the load. The guide ribs 6 may be situated in either the depicted location in the forkway created by the notches 7, in the forkway created by the notches 23, or in both forkways. This embodiment is not depicted in full, but its creation would be readily apparent to those skilled in the art.
The construction of an embodiment of the pallet may use very lightweight and economical materials in its construction. Recognizing that various embodiments need not be limited to the following materials or dimensions, the preferred material for use to manufacture the stringers is a fast-growth timber product, such as low-grade two-by-fours created from black poplar trees. A squared piece of lumber 17 as shown in FIG.
8, which would have an end dimension of about one-and-a-half inches by about three-and-a-half inches, can be split in three to create three pieces 18 with a cross section of about seven-sixteenths of an inch by about three-and-a-half inches. Each of these pieces can then be used to create a lower stringer 1 a-1 e or an upper stringer 2a-2e. This is an enhancement over existing products, which are limited to a minimum stringer thickness of eleven-sixteenths of an inch, because it may save on both costs and weight.
FIG. 9 shows a perspective view of one embodiment of the invention with the optional deck 15 installed, and FIG. 10 shows an exploded view of the same.
The deck 15 is a flat piece of material, preferably the same material used in the construction of the pallet as mentioned hereinbefore. The deck is useful for several applications, including the manipulation of small materials that the bare skeleton embodiment of the pallet would be unable to support due to their size. The underside of the deck 15 contains mortises 16 which accept the upper edges of both the lower stringers la-le and the upper stringers 2a-2e. This mortising may provide stability to the pallet, helping to prevent or reduce racking. Also, the mortising reduces the height of the pallet when the deck 15 is installed. The deck 15 can be constructed of any suitable material. Plywood is FRGS\27712AP_DOC -9-appropriate. The preferred decking material is the same fast-growth timber products used for the stringers, which can be formed into planks to create the deck 15.
FIG. 11 shows a front elevation of the deck 15 designed to fit one embodiment of the invention. This illustration shows the ends of the mortising 16, which, in this view, is arra.nged to accept the top edges of the lower stringers la-1e. The mortising 16 is of an appropriate width to provide a snug fit with the upper edges of the lower stringers 1 a-1 e and the upper edges of the upper stringers 2a-2e.
FIG. 12 shows a side elevation of the deck 15 designed to fit one embodiment of the invention. This illustration shows the ends of the mortising 16, which, in this view, is arranged to accept the top edges of the upper stringers 2a-2e.
FIG. 13 shows a perspective view of the underside of the deck 15 designed to fit one embodiment of the invention. In this view, the pattern of mortising 16 is apparent, and is shown to match the pattern of the upper surface of the lower stringers 1 a-1 e and the upper stringers 2a-2e as shown in FIG. 10. The mortising 16 is deep enough in the deck 15 to ensure stability, preferably at least half way through the deck 15.
The pallet should be reasonably stable when assembled due to the snug fit of the notches and mortises. For added stability, it is preferred to use fastening means to reinforce each joint. The preferred means is to glue each joint and each mortise, as this can provide for the easiest recyclability, but other means such as nails or staples could also be used.
FIG. 14 shows a detail perspective view of one embodiment of the invention, and illustrates one embodiment of the installation of a repair stringer. In this illustration, damaged upper stringer 2a' has sustained an injury D. The repair stringer 5 has similar dimensions to the existing upper stringers 2a-2e, but has extended slots 11', 12', and 20' so as to engage the notches 3 of the lower stringers la-le instead of the respective slots 9, 10, and 19 (visible in FIG. 6B). The repair stringer 5 is dropped into place along the dashed lines, and provides support when attached to the damaged upper stringer 2a'.
FIGS. 15A-15F illustrate a method 15000 for constructing a pallet. From a start block (FIGURE 15A), the method 15000 proceeds to a set of method steps 15002, defined between a continuation terminal ("Terminal A") and an exit terminal ("Terminal B"). The set of method steps 15002 between Terminals A-B describe the processing of pieces of timber to form a first set of long stringers, about 48 inches long, of a pallet.

FRGS12771 znP noc -10-From Terminal A (FIGURE 15C), the method 15000 proceeds to block 15010 where a piece of timber is obtained from a fast growth species of tree. At block 15012, the piece of timber is squared and trimmed, each side of the squared piece of lumber having a suitable width of about 3 1/2 inches and a suitable length of about 48 inches. A
saw is provided, the saw having teeth that are arranged to create slots, notches, and rib slots periodically across the piece of lumber. See block 15014. At block 15016, this saw is activated to form slots, notches, and rib slots on the piece of lumber.
Next, at block 15018, a saw is used to cut the piece of lumber lengthwise into stringers, each having a suitable width of about 7/16 of an inch, and the method proceeds to exit Terminal B.
From exit Terminal B (FIGURE 15A), the method 15000 proceeds to another continuation terminal ("Terminal C") and an exit terminal ("Terminal D"). The set of method steps 15004 between Terminals C-D describe the processing of pieces of timber to form a second set of short stringers, about 40 inches long, of a pallet.
From Terminal C (FIGURE 15D), the method proceeds to block 15020 where a piece of timber =is obtained from a fast growth species of tree. At block 15022, the piece of timber is squared and trimmed, each side of the squared piece of lumber having a suitable width of about 3 1/2 inches and a suitable length of about 40 inches. The saw from step 15014 is then provided in block 15024, the saw having teeth that are arranged similarly to the saw in step 15014 so as to create slots, notches, and rib slots periodically across the piece of lumber. It will be appreciated by one skilled in the art that the reuse of this saw may result in a similar pattern of slots, notches, and rib slots. At block 15026, this saw is activated to form slots, notches, and rib slots on the piece of lumber. Next, at block 15028, a saw is used to cut the piece of lumber lengthwise into stringers, each having a suitable width of about 7/16 of an inch, and the method proceeds to exit Terminal D.
From exit Terminal D (FIGURE l5A), the method 15000 proceeds to another continuation terminal ("Terminal E") and an exit terminal ("Terminal F"). The set of method steps 15006 between Terminals E-F describe the construction of guide ribs and the assembly of a pallet. From Terminal E (FIGURE 15E), the method proceeds to block 15030 where the guide ribs are constructed from a suitable material. Assembly of the pallet begins in block 15032, where the short stringers are arranged with their notches facing upwards. Next, in block 15034, glue is applied to each of the slots in the short stringer, and in the corresponding slots in the long stringers. In block 15036, the long FAGS'27712AP.DOC -1 1-stringers are arranged with the notches facing downward so that the slots interlock with the corresponding upward-facing slots on the short stringers. Next, in block 15038, glue is applied to the guide rib slots on the long stringers, and the guide ribs are put in place.
The method 15000 then continues to exit Terminal F.
From exit Terminal F (FIGURE 15A), the method 15000 proceeds to a continuation terminal ("Terminal F l"). From Terminal Fl, the method 15000 continues (FIGURE 15B) to another continuation terminal ("Terminal G") and an exit terminal ("Terminal H"). The set of method steps 15008 between Terminals G-H describe the manufacture and attachment of an optional deck that can fit over a pallet formed from the first and second sets of stringers. From Terminal G (FIGURE 15F), the method proceeds to block 15040 where boards of about 1/2 of an inch thickness and an appropriate length of about 48 inches are obtained. Next, in block 15042, the boards are glued together to form a thin, flat deck of horizontal dimensions similar to the upper surface dimensions of the pallet and of about 1/2 of an inch thickness. In block 15044, a mortising tool is provided that is capable of cutting mortises in the deck of an appropriate width of about 7/16 of an inch and an appropriate depth of about 1/4 of an inch. The width of these mortises should be appropriate to snugly fit the top edges of the stringers.
Next, in block 15046, the tool is activated and mortises are cut in the deck to align with the top surfaces of the pallet. In block 15048, glue is applied to the mortises and to the upper surfaces of the pallet, and the deck is installed. The method 15000 then continues to exit Terminal H, and from Terminal H to a finish block (FIGURE 15B).
It will be appreciated by one skilled in the art that instead of obtaining timber from forest land 15010, 15020 and squaring it off 15012, 15022 to obtain the necessary lumber, this process can use lumber of similar dimensions purchased on the open market as time and economics require.
FIG. 16 illustrates a method 16000 for repairing a pallet. From a start block, the method 16000 proceeds to block 16002, where a stringer left over from the manufacture of the pallet is obtained. Next, in block 16004, cutting means such as a saw or chisel are used to extend the slots of the stringer suitably far to engage an opposing notch instead of a slot. Then, in block 16006, fastening means such as glue, staples, screws, or the like are used to attach the stringer to the broken stringer, such that the slots on the stringer engage FRGS\27712AP.DOC -12-the opposing notches in the orthogonal stringer. The method 16000 then proceeds to a finish block.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.

FRG5\27712AP.DOC -13-

Claims

1. A pallet, comprising:
a set of lower stringers that are spaced apart, each lower stringer including a set of outer slots, a set of inner slots, and a set of projections, each projection being situated at either a distal end or a proximal end of a lower stringer, each outer slot being adjacent to a projection, each inner slot being adjacent to an outer slot;
a set of upper stringers that are spaced apart, each upper stringer including a set of outer slots, a set of inner slots, a set of rib slots, a set of notches, and a set of projections, each projection being situated at either a distal end or a proximal end of an upper stringer, each outer slot being adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end, each rib slot being situated at approximately the center of each notch; and a set of ribs that sit into the set of rib slots of the upper stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load, the sets of outer slots engaging one another and the set of inner slots engaging one another to form forkways by the set of notches, from the set of rib slots the set of ribs protruding into the forkways to guide fingers of lifting machinery so the pallet may be possessed.

2. The pallet of Claim 1, wherein the set of lower stringers is secured to the set of upper stringers with fastening means.

3. The pallet of Claim 2, wherein the fastening means includes glue.

4. The pallet of Claim 1, wherein each of the ribs situated in the rib slots of the upper stringers is one solid piece of material that runs substantially from one edge of the pallet to another edge of the pallet.

5. The pallet of Claim 1, wherein each stringer is of approximate half-inch thickness with the thickness disposed horizontally and of approximate four-inch width with the width disposed vertically.

6. The pallet of Claim 5, wherein each stringer is created from a two-by-four or four-by-four that has been cut lengthwise into substantially equal-sized pieces of approximate half-inch thickness and of approximate four-inch width.

7. The pallet of Claim 1, further comprising a repaired stringer that includes a set of outer slots, a set of inner slots, and a set of projections, the repaired stringer being fastened adjacent to either a lower stringer or an upper stringer that is injured.

8. The pallet of Claim 1, wherein each of the lower stringers includes a set of notches, each notch being adjacent to an outer slot at one end and to an inner slot at another end such that when the set of lower stringers and the set of upper stringers are orthogonally mated to cause the sets of outer slots to engage one another and the set of inner slots to engage one another, forkways are formed by the set of notches.

9. The pallet of Claim 8, wherein each of the lower stringers includes a set of rib slots, each rib slot being situated at approximately the center of each notch; and a set of ribs that sit into the set of rib slots of the lower stringers when the set of lower stringers and the set of upper stringers are orthogonally mated to create a structure capable of supporting a load, and to cause the sets of outer slots to engage one another and the set of inner slots to engage one another to form forkways by the set of notches, from the set of rib slots of the lower stringers the set of ribs protruding into the forkways to guide fingers of lifting machinery so the pallet may be possessed.

10. The pallet of Claim 9, wherein each of the ribs situated in the rib slots of the lower stringers is one solid piece of material that runs substantially from one edge of the pallet to another edge of the pallet.

11. The pallet of Claim 10, wherein the ribs situated in the rib slots of the lower stringers and the ribs situated in the rib slots of the upper stringers are mortised at their intersections and interlock orthogonally.

12. A pallet, comprising:
a set of lower stringers that are spaced apart, each lower stringer including a set of outer slots, a set of inner slots, and a set of projections, each projection being situated at either a distal end or a proximal end of a lower stringer, each outer slot being adjacent to a projection, each inner slot being adjacent to the outer slot;
a set of upper stringers that are spaced apart, each upper stringer including a set of outer slots, a set of inner slots, a set of notches, and a set of projections, each projection being situated at either a distal end or a proximal end of an upper stringer, each outer slot being adjacent to a projection, each notch being adjacent to an outer slot at one end and to an inner slot at another end; and a deck which bottom is cut to form a set of mortises, a first subset of the mortises being spaced apart and a second subset of the mortises being spaced apart and orthogonal to the first subset of the mortises, the set of mortises receiving a structure created when the sets of upper stringers and lower stringers are orthogonally mated so as to reduce racking.

13. The pallet of Claim 12, wherein the deck is dimensioned substantially the same as the horizontal length and width of the pallet.

14. The pallet of Claim 12, wherein the deck is secured to the pallet via fastening means.

15. The pallet of Claim 14, wherein the fastening means includes glue.

16. The pallet of Claim 12, wherein the deck is formed from planks of the same material used to create the rest of the pallet.

17. A method for manufacturing a pallet, comprising:
obtaining lumber of approximate four-inch height;
configuring the teeth of a saw to cut notches and slots in the lumber;
using the saw to cut the notches and slots in the lumber in appropriate locations for a set of upper stringers;

using the same saw to cut similar notches and slots in the lumber in appropriate locations for a set of lower stringers;
using a different saw to divide the notched lumber lengthwise into pieces of approximate four-inch height and approximate one-half-inch width;
arranging the upper stringers and lower stringers orthogonally in an interlocking manner;
creating a set of ribs; and attaching the set of ribs.

18. The method of Claim 17, wherein the lumber is low-grade two-by-fours;

19. The method of Claim 17, wherein the lumber is obtained by squaring off timber from a fast-growth species of tree;

20. The method of Claim 19, where the species of tree is black poplar.