US20050056193A1

US20050056193A1 - Pallet

Info

Publication number: US20050056193A1
Application number: US10/660,067
Authority: US
Inventors: Bart Laender; Vishnu Naidu; Richard Coulcher; Anthony Dillen; Tiemen Dillen
Original assignee: CHEP International Inc
Current assignee: Chep Technology Pty Ltd
Priority date: 2003-09-11
Filing date: 2003-09-11
Publication date: 2005-03-17
Also published as: WO2005025998A2; WO2005025998A3; EP1694569A2

Abstract

A pallet having a top support member for supporting cargo and support elements for supporting the top support member above a surface and for creating one or more cavities for receiving a lifting member for moving the pallet. The support elements may have an oval cross-section for guiding the lifting members into the cavity. The support elements may be formed from a composite material for increased strength and durability.

Description

FIELD OF THE INVENTION

The invention is directed generally to pallets, and more particularly, to cargo pallets having cavities for receiving forklift tines.

BACKGROUND

Wood pallets are used to transport and store a variety of different kinds of cargo. Conventional wood pallets are formed from a top support member and a bottom support member separated by a plurality of cavities sized to receive forklift tines. The top and bottom support members are separated by a plurality of wooden support blocks, which are positioned to form the plurality of cavities. The top and bottom support members are often formed from a plurality of 1 inch by 4 inch lumber, and the support blocks are often formed from 2 inch by 4 inch lumber or 4 inch by 4 inch lumber.
During use, forklift tines are inserted into the cavities to lift the pallets. Often times, the tines of these devices are not inserted into the cavities in the correct location beneath the top support members. Rather, the tines first strike the support members, which either destroys the pallet or damages the support members. Pallets that are destroyed must be replaced, which often delays delivery schedules and increases costs. A damaged pallet is weakened and often requires replacement before expiration of a normal lifespan of the pallet. Thus, a pallet having support blocks capable of withstanding blows from forklift tines is needed.

SUMMARY OF THE INVENTION

This invention is directed to a pallet formed from one or more top support members adapted to support cargo and having at least one substantially flat top surface and a bottom surface. The top support member is supported by two or more support blocks, which may be coupled to the bottom surface of the at least one top support member for positioning the top surface of the pallet above a surface, to allow a lifting member to be placed underneath the top support member for moving the pallet. The support blocks may have a top surface, a bottom surface, and a side surface and may be spaced apart a sufficient distance to form one or more cavities for receiving a lifting member. The lifting member may be, but is not limited to, tines for a forklift, a pallet jack, a reach truck, or other similar device. The support blocks may have a side surface forming a generally oval cross-section, which may guide lifting members into the cavities beneath the top support member. The cross-section may be formed from a single curved line, two or more curved or straight lines, or a combination of curved and straight lines. The cross-section of the support block may have a first end and a second end along a longitudinal axis of the support block. The support blocks may be aligned so that the first end is positioned proximate to a side surface of the top support member and the longitudinal axis of the support block is aligned so that the first end of the support device guides a lifting member into a lifting position under the top support member.
The support blocks may be formed from a composite material. In at least one embodiment, the composite material may be a combination of a cellular material and at least one thermoplastic resin. The cellular material may be, but is not limited to, a wood species, linen flax shives, bagasse from sugar cane, jute, and bamboo. The thermoplastic resin may be a polypropylene, a polyethylene, or other appropriate thermoplastic resin, or any combination thereof. The composite material may provide increased strength to the support blocks in comparison with support blocks formed from 100 percent wood. The composite material may provide increased wear resistance and, therefore, increased lifespan. The composite material is superior to an all plastic material in that the composite material is nailable, easily machinable, easier to paint, and lighter.
In at least one embodiment, the pallet may be formed from a top support member formed from three cross supports coupled to a plate. Nine or more support blocks may be formed into at least three rows beneath the top support member and positioned generally parallel to each other forming at least two cavities to receive one or more lifting members. A bottom support member may be coupled to a bottom surface of the support blocks to provide a stable surface upon which the pallet rests.
An advantage of some embodiments of this invention is that the exterior shape of the support blocks form a guide for positioning the lifting members under the top support member of the pallet. Thus, loading a pallet of this invention requires less time to load because time is not lost in aligning the lifting member with the cavities beneath the top support member.
Another advantage of some embodiments of this invention is that the exterior shape and hard, low friction surface tends to deflect blows received from lifting members striking the support blocks rather than absorbing the forces delivered by the lifting members without redirecting the lifting members. This, in effect, limits damage to products supported by the pallet. In contrast, a hollow plastic block often dents and cups the point of a lifting member upon being struck.
Yet another advantage of some embodiments of this invention is that the composite material increases the strength and durability of the support blocks, thereby increasing the lifespan of the pallet.
These and other features and advantages of the present invention will become apparent after review of the following drawings and detailed description of the disclosed embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of this invention and, together with the description, disclose various aspects of the invention. These figures include the following:
FIG. 1 is perspective view of a pallet according to one or more aspects of this invention;
FIG. 2 is a side view of a support block of this invention;
FIG. 3 is a top view of a support block of this invention;
FIG. 4 is a top view of a support block having an alternatively shaped cross-section;
FIG. 5 is a top view of a support block have another alternatively shaped cross-section;
FIG. 6 is a top view of a support block having yet another alternatively shaped cross-section;
FIG. 7 is a top view of a support block having still another alternatively shaped cross-section;
FIG. 8 is a top view of a support block having another alternatively shaped cross-section;
FIG. 9 is a top view of a support block having yet another alternatively shaped cross-section; and
FIG. 10 is a top view of a support block having still another alternatively shaped cross-section.

DETAILED DESCRIPTION

FIGS. 1-10 illustrate a pallet 10, and related components thereof, configured to support cargo on one or more top support members 12. The top support member 12 is supported above a surface 14 using two or more support blocks 16 positioned to allow lifting members 18 to be placed under the top support member 12 to lift the pallet 10 and the cargo supported by the pallet 10. The top support member 12 may have any suitable shape. In at least one embodiment, as shown in FIG. 1, the top support member 12 may be composed of a generally flat top surface 20 and a bottom surface 22. In other embodiments, top support member 12 may have top surfaces 20 that are not flat. In some embodiments, the top surface 20 may include one or more coatings or other textured materials to prevent cargo from slipping or moving on the top surface 20. In at least one embodiment, as shown in FIG. 1, the top support member 12 may be formed from three cross supports 24 positioned generally parallel to each other and a plate 26 coupled to a top surface 20 of the three cross supports 24 forming the top surface 20.
The support blocks 16 may be positioned so that a lifting member 18 may be positioned between the surface 14 and the bottom surface 22 to lift the pallet 10 in a stable manner. The lifting member 18 may be, but is not limited to: one or more tines of a forklift, pallet jack, reach truck, or other lifting device; one or more cables, or other devices having appropriate strength. In at least one embodiment, the support blocks 16 may have a height between about 3 inches and about 6 inches. A top surface 28 of the support block 16, as shown in FIG. 3, may be configured to be attached to the bottom surface 22 of the top support member 12. The support block 16 may have a bottom surface 30, as shown in FIG. 2, configured to rest on the surface 14 and provide the pallet 10 with a stable support surface. In at least one embodiment, the bottom surface of the support block 16 may be coupled to a bottom support member 32 configured to rest stably on the surface 14. The support block 16 may be configured to guide lifting members 18 into position under the top support member 12, as shown in FIG. 1.
The support block 16 may have an oval cross-section, which shall be defined herein to include elliptical shapes as shown in FIG. 4, teardrop shapes as shown in FIG. 7, and egg shapes as shown in FIG. 8, as well as other suitable curvilinear shapes as shown in FIG. 5, and other elongated shapes having linear and/or curvilinear sides such as an elongated hexagon as shown in FIG. 6, a diamond shape as shown in FIG. 9, and a kite shape as shown in FIG. 10 in which one end has a more gradual transition than the other end. Examples of suitable oval cross-sections are shown in FIGS. 3 and 4, where a first distance 42 is greater than a second distance 44. The oval cross-section may be formed from a single continuous line, as shown in FIGS. 3 and 4.
In other embodiments, the cross section of the support block 16 may be formed from a combination of curved lines and at least substantially straight lines, as shown in FIG. 5. The embodiment shown in FIG. 5 may have a first substantially flat surface forming the first end 34 and a second substantially flat surface forming the second end 36. This embodiment may also have a third substantially flat surface 41 positioned on a side surface 39 of the support block 16 between the first and second ends 34, 36, and a fourth substantially flat side 43 on a side surface 39 of the support block 16 between the first and second ends 34, 36 and opposite to the third substantially flat surface 41, as well as rounded surfaces 35.
In other embodiments, the cross section of the support block 16 may be formed from a plurality of substantially straight lines, as shown in FIG. 6, which may form a hexagon having six sides or another shape having multiple sides.
The support block 16 may have a first end 34 and a second end 36 positioned along a longitudinal axis 38. The longitudinal axis 38 may be positioned between the first end 34 and the second end 36. The first end 34 may be positioned proximate to a side surface 40 of the top support member 12, as shown in FIG. 1. The longitudinal axis 38 may be aligned relative to the top support member 12 so that the first end 34 guides a lifting member 18 into position under the top support member 12. In at least one embodiment, the longitudinal axis 38 may be generally parallel to a side surface 40 the top support member 12. By configuring the first distance 42 of the support block 16 to be longer than the second distance 44, the support block 16 is able to redirect misaligned lifting members 18 into a cavity 46 under the top support member 12.
The support block 16 may be formed from a composite material. In at least one embodiment, the composite material may be formed from at least one species of a cellular material and a thermoplastic resin, or a combination of a cellular material and a thermosetting resin, or any combination thereof. The cellular material may be, but is not limited to, a wood species, linen flax shives, bagasse from sugar cane, jute, rice husks, paper fiber, recycled paper, nut shells, cornhusks, other agricultural products, and bamboo. The composite material may have better impact strength and higher nail retention than wood. In particular, the composite material may have a fork tine compression strength that is about 2.5 times greater the fork tine compression strength of a wooden block made of standard southern yellow pine. For instance, the time compression strength of the composite material may be about 4,225 pounds at 23 degrees Celsius per composite block having dimensions of about 4.61 inches long, 3.77 inches wide, and 3.51 inches high. In addition, the nail retention strength may be about 50 percent better than the nail retention strength of standard southern yellow pine. The composite material may also be generally water resistant such that the composite material may not absorb more than five percent water by weight and has less than two percent enlargement in any direction when submerged in water at 20 degrees Celsius for 24 hours. In addition, in at least one embodiment, the composite material does not distort when placed in water at 100 degrees Celsius for one hour.
The concentration of wood species in the composite may be between about one percent and about 99 percent, and more preferably, between about 40 percent and about 60 percent, although the invention is not limited to these concentration ranges. The wood species may be in a wood flour form having particle sizes between about 0.1 millimeters (mm) and about 1.0 mm, although the invention is not limited to use of a wood flour or to a wood flour having a particle size falling within this range of particle sizes.
The cellular material may also be formed from particles having diameters between about 0.05 mm and about 4 mm, preferably between 0.1 mm and 1 mm, and most preferably between about 0.177 mm to about 0.42 mm. The cellular material may be formed from wood particles having different diameters. Wood particles of these sizes can provide increased durability of the support block 16.
The thermoplastic resin may be a polyolefin, such as a polypropylene or a polyethylene, or other thermoplastic resin, or any combination thereof. The polyethylene may have a density between about 0.9 grams per cubic centimeter and about 0.98 grams per centimeter, although the invention is not limited to resins having densities in this range. More particularly, the polyethylene may be a linear low density polyethylene, an ultra low density polyethylene, a low density polyethylene, a high density polyethylene, or an ultra high molecular weight polyethylene, or any combination thereof.
The polypropylene may be formed from a homopolymer or a copolymer having a density between about 0.80 grams per cubic centimeter and about 0.99 grams per cubic centimeter, although the invention is not limited to resins having densities in this range. The thermosetting resin may be, but is not limited to, a polyester, an epoxy, or vinylester. Support blocks 16 formed from the composite material are capable of withstanding repeated blows from lifting members 18.
In at least one embodiment, the pallet 10 may have a plurality of support blocks 16 coupled to the bottom surface 22 of the top support member 12. There may be nine support blocks, as shown in FIG. 1, wherein a first group of three support blocks 16 may be positioned in a first row 48, a second group of three support blocks may be positioned in a second row 50, and a third group of three support blocks may be positioned in a third row 52. The first, second, and third rows 48, 50, 52 of support blocks 16 may be positioned generally parallel to each other, such that the first, second, and third rows 48, 50, 52 of support blocks 16 support the cross supports 24. Each row 48, 50, 52 may include two support blocks 16 positioned proximate to the side surface 40 of the top support member 12 and aligned so that the first end 34 of each support block 16 may guide a lifting member 18 into a lifting position under the at least one top support member 12.
The terms and expressions which have been employed herein are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding any equivalents of the features shown and described or portions thereof. Having thus described the invention in detail, it should be apparent that various modifications can be made in the present invention without departing from the spirit and scope of the following claims.

Claims

1. A pallet, comprising:

at least one top support member adapted to support cargo and having at least one substantially flat top surface and a bottom surface;

at least two support blocks coupled to the at least one top support member for positioning the top surface of the pallet above a surface, the at least two support blocks having at least a top surface, a bottom surface, and a side surface;

wherein the at least two support blocks are spaced apart a sufficient distance to receive a lifting member; and

wherein at least one of the support blocks has an oval cross-section having a first end and a second end along a longitudinal axis of the support block; and

wherein the first end is positioned proximate to a side surface of the at least one top support member and the longitudinal axis of the support block is aligned so that the first end guides a lifting member into a lifting position under the at least one top support member.

2. The pallet of claim 1, further comprising at least one bottom support member coupled to the bottom surfaces of the at least two support blocks, wherein the bottom support member further comprises a bottom surface configured to rest stably on a flat surface.

3. The pallet of claim 1, wherein the at least two support blocks comprise nine support blocks, wherein a first group of three support blocks are positioned in a first row, a second group of three support blocks are positioned in a second row, and a third group of three support blocks are positioned in a third row.

4. The pallet of claim 3, wherein the first, second, and third rows are positioned substantially parallel to each other and the support blocks positioned proximate to an outer edge of the top support member are aligned so that a first end of the support blocks guides a lifting member into a lifting position under the at least one top support member.

5. The pallet of claim 4, wherein the top support member is formed from at least three cross supports positioned generally parallel to each other, wherein the first, second, and third rows of support blocks support the three cross supports, and wherein the top support member further comprises a plate coupled to a top surface of the three cross supports and forming the top surface of the top support member.

6. The pallet of claim 1, wherein at least one of the at least two support blocks is formed from a composite material comprising at least one cellular material and a thermoplastic resin.

7. The pallet of claim 6, wherein the composite material is selected from the group consisting of polypropylene and polyethylene.

8. The pallet of claim 7, wherein the polyethylene has a density between about 0.9 grams per cubic centimeter and about 0.98 grams per cubic centimeter.

9. The pallet of claim 7, wherein the thermoplastic resin is selected from the group consisting of a linear low density polyethylene, an ultra low density polyethylene, a low density polyethylene, a high density polyethylene, and an ultra high molecular weight polyethylene.

10. The pallet of claim 7, wherein the polypropylene is formed from the group consisting of homopolymers and copolymers having densities between about 0.80 grams per cubic centimeter and about 0.99 grams per cubic centimeter.

11. The pallet of claim 6, wherein the at least one cellular material is comprised of wood flour having a particle size between about 0.1 millimeters and about 1.0 millimeters.

12. The pallet of claim 6, wherein the concentration of the at least one cellular material in the composite is between about 40 percent and about 60 percent.

13. The pallet of claim 6, wherein the cellular material is formed from at least one wood particle having diameters between about 0.05 mm and about 4 mm.

14. The pallet of claim 13, wherein the cellular material is formed from at least one wood particle having diameters between preferably between 0.1 mm and 1 mm.

15. The pallet of claim 14, wherein the cellular material is formed from at least one wood particle having diameters between about 0.177 mm to about 0.42 mm.

16. The pallet of claim 6, wherein the cellular material is selected from the group consisting of a wood species, linen flax shives, bagasse from sugar cane, jute, rice husks, paper fiber, recycled paper, nut shells, cornhusks, and bamboo.

17. The pallet of claim 1, wherein at least one of the at least two support blocks is formed from a composite material comprising at least one cellular material and at least one thermosetting resin.

18. The pallet of claim 17, wherein the at least one thermosetting resin is selected from the group comprising polyesters, epoxies, and vinylesters.

19. The pallet of claim 1, wherein the at least one support block with an oval cross-section further comprises a first substantially flat surface comprising a portion of the first end and a second substantially flat surface comprising a portion of the second end.

20. The pallet of claim 19, wherein the at least one support with an oval cross-section further comprises a third substantially flat surface positioned on a side of the support block between the first and second ends and a fourth substantially flat surface positioned on a side of the support block between the first and second ends and opposite to the third substantially flat surface.

21. The pallet of claim 19, wherein the at least one support with an oval cross-section is selected from the group consisting of six substantially flat sides forming a hexagon, a tear drop shape, an egg shape, an elongated hexagon, a diamond shape, and a kite shape.

22. A pallet, comprising:

a plurality of support blocks coupled to the bottom surface of the at least one top support member positioning the top surface of the pallet above a surface and forming at least two cavities for receiving a lifting member, the at least two support blocks having at least a top surface, a bottom surface, and a side surface;

wherein at least one of the support blocks has an oval cross-section formed from a composite comprising at least one wood species and a thermoplastic resin, and having a first end and a second end along a longitudinal axis of the support block and the first end is positioned proximate to a side surface of the at least one top support member and the longitudinal axis of the support block is aligned so that the first end guides a lifting member into a lifting position under the at least one top support member.

23. The pallet of claim 22, further comprising at least one bottom support member coupled to the bottom surfaces of the at least two support blocks, wherein the bottom support member further comprises a bottom surface configured to rest stably on a flat surface.

24. The pallet of claim 22, wherein the at least two support blocks comprise nine support blocks, wherein a first group of three support blocks are positioned in a first row, a second group of three support blocks are positioned in a second row, and a third group of three support blocks are positioned in a third row.

25. The pallet of claim 24, wherein the first, second, and third rows are positioned substantially parallel to each other and the support blocks positioned proximate to an outer edge of the top support member are aligned so that a first end of the support blocks guides a lifting member into a lifting position under the at least one top support member.

26. The pallet of claim 25, wherein the top support member is formed from at least three cross supports positioned generally parallel to each other, wherein the first, second, and third rows of support blocks support the three cross supports, and wherein the top support member further comprises a plate coupled to a top surface of the three cross supports and forming the top surface of the top support member.

27. The pallet of claim 22, wherein at least one of the two support blocks is formed from a composite material comprising at least one cellular material and a thermoplastic resin.

28. The pallet of claim 27, wherein the composite material is selected from the group consisting of polypropylene and polyethylene.

29. The pallet of claim 27, wherein the polyethylene has a density between about 0.9 grams per cubic centimeter and about 0.98 grams per cubic centimeter.

30. The pallet of claim 28, wherein the thermoplastic resin is be selected from the group consisting of a linear low density polyethylene, an ultra low density polyethylene, a low density polyethylene, a high density polyethylene, and an ultra high molecular weight polyethylene.

31. The pallet of claim 29, wherein the polypropylene is formed from the group consisting of homopolymers and copolymers having densities between about 0.80 grams per cubic centimeter and about 0.99 grams per cubic centimeter.

32. The pallet of claim 27, wherein the at least one cellular material is comprised of wood flour having a particle size between about 0.1 millimeters and about 1.0 millimeters.

33. The pallet of claim 27, wherein the concentration of the at least one cellular material in the composite is between about 40 percent and about 60 percent.

34. The pallet of claim 28, wherein the cellular material is formed from at least one wood particle having diameters between about 0.05 mm and about 4 mm.

35. The pallet of claim 34, wherein the cellular material is formed from at least one wood particle having diameters between preferably between 0.1 mm and 1 mm.

36. The pallet of claim 35, wherein the cellular material is formed from at least one wood particle having diameters between about 0.177 mm to about 0.42 mm.

37. The pallet of claim 27, wherein the cellular material is selected from the group consisting of a wood species, linen flax shives, bagasse from sugar cane, jute, rice husks, paper fiber, recycled paper, nut shells, cornhusks, and bamboo.

38. The pallet of claim 22, wherein at least one of the support blocks is formed from a composite material comprising at least one cellular material and at least one thermosetting resin.

39. The pallet of claim 38, wherein the at least one thermosetting resin is selected from the group comprising polyesters, epoxies, and vinylesters.

40. The pallet of claim 22, wherein the at least one support block with an oval cross-section further comprises a first substantially flat surface comprising a portion of the first end and a second substantially flat surface comprising a portion of the second end.

41. The pallet of claim 40, wherein the at least one support with an oval cross-section further comprises a third substantially flat surface positioned on a side of the support block between the first and second ends and a fourth substantially flat surface positioned on a side of the support block between the first and second ends and opposite to the third substantially flat surface.

42. The pallet of claim 22, wherein the at least one support with an oval cross-section is selected from the group consisting of six substantially flat sides forming a hexagon, a tear drop shape, an egg shape, an elongated hexagon, a diamond shape, and a kite shape.

43. A pallet support for supporting a top support member of a pallet and creating at least one cavity under the top support member for receiving a lifting member capable of lifting the pallet off of a surface, comprising:

a body having a top surface, a bottom surface generally opposite to the top surface, and at least one side wall, the top surface adapted to be coupled to a bottom surface of a top support member and the bottom surface adapted to support the top support member;

wherein the body is formed from a composite comprising at least one cellular material and at least one plastic.

44. The pallet of claim 43, wherein the plastic is selected from the group consisting of polypropylene and polyethylene.

45. The pallet of claim 44, wherein the polyethylene has a density between about 0.9 grams per cubic centimeter and about 0.98 grams per cubic centimeter.

46. The pallet of claim 44, wherein the thermoplastic resin is be selected from the group consisting of a linear low density polyethylene, an ultra low density polyethylene, a low density polyethylene, a high density polyethylene, and an ultra high molecular weight polyethylene.

47. The pallet of claim 4, wherein the polypropylene is formed from the group consisting of homopolymers and copolymers having densities between about 0.80 grams per cubic centimeter and about 0.99 grams per cubic centimeter.

48. The pallet of claim 43, wherein the at least one cellular material is comprised of wood flour having a particle size between about 0.1 millimeters and about 1.0 millimeters.

49. The pallet of claim 43, wherein the concentration of the at least one cellular material in the composite is between about 40 percent and about 60 percent.

50. The pallet of claim 43, wherein the cellular material is formed from at least one wood particle having diameters between about 0.05 mm and about 4 mm.

51. The pallet of claim 50, wherein the cellular material is formed from at least one wood particle having diameters between preferably between 0.1 mm and 1 mm.

52. The pallet of claim 51, wherein the cellular material is formed from at least one wood particle having diameters between about 0.177 mm to about 0.42 mm.

53. The pallet of claim 43, wherein the cellular material is selected from the group consisting of a wood species, linen flax shives, bagasse from sugar cane, jute, rice husks, paper fiber, recycled paper, nut shells, cornhusks, and bamboo.

54. The pallet of claim 43, wherein the plastic is at least one thermosetting resin.

55. The pallet of claim 54, wherein the at least one thermosetting resin is selected from the group comprising polyesters, epoxies, and vinylesters.

56. The pallet of claim 43, wherein at least one of the support blocks has an oval cross-section having a first end and a second end along a longitudinal axis of the support block.

57. The pallet of claim 56, wherein the at least one support block with an oval cross-section further comprises a first substantially flat surface comprising a portion of the first end and a second substantially flat surface comprising a portion of the second end.

58. The pallet of claim 57, wherein the at least one support with an oval cross-section further comprises a third substantially flat surface positioned on a side of the support block between the first and second ends and a fourth substantially flat surface positioned on a side of the support block between the first and second ends and opposite to the third substantially flat surface.

59. The pallet of claim 57, wherein the at least one support with an oval cross-section is selected from the group consisting of six substantially flat sides forming a hexagon, a tear drop shape, an egg shape, an elongated hexagon, a diamond shape, and a kite shape.

60. A pallet support for supporting a top support member of a pallet and creating at least one cavity under the top support member for receiving a lifting member capable of lifting the pallet off of a surface, comprising:

wherein the body has an oval cross-section and includes a first end and a second end along a longitudinal axis of the support block.

61. The pallet of claim 60, wherein the pallet support having an oval cross-section further comprises a first substantially flat surface comprising a portion of the first end and a second substantially flat surface comprising a portion of the second end.

62. The pallet of claim 60, wherein the pallet support with an oval cross-section further comprises a third substantially flat surface positioned on a side of the support block between the first and second ends and a fourth substantially flat surface positioned on a side of the support block between the first and second ends and opposite to the third substantially flat surface.

63. The pallet of claim 62, wherein the pallet support with an oval cross-section is selected from the group consisting of six substantially flat sides forming a hexagon, a tear drop shape, an egg shape, an elongated hexagon, a diamond shape, and a kite shape.