PALLET ASSEMBLY AND METHOD OF USE

Description

REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 63/666,957, filed on Jul. 2, 2024; the disclosure of which is incorporated herein by reference.

TECHNICAL FIELD

This disclosure is directed to a pallet assembly for packaging and transporting a building kit.

BACKGROUND ART

Various types of building kits, including shed kits, children playset kits, pergola kits, gazebo kits, and other similar building kits, are commonly purchased for residential and/or commercial uses. Such purchasing of these kits may be cost effective for customers rather than buying a fully constructed building that is delivered to the customers' properties or having such building being constructed on the customers' properties. Such purchasing of these building kits may also provide customers with do-it-yourself projects or DIY projects while still achieving a high-quality build with a professional finish. Such purchasing of these building kits may also provide customers with more customization and/or personalization when constructing the building.

While such building kits are desirable, systems and/or assemblies that are needed to transport these kits are issues for manufacturers of these building kits. In one example, manufacturers of these building kits may have to ship large and cumbersome building materials in one or more freights in order for the customer to receive the entire building kit. As such, customers of these building kits must incur additional charges and fees due to the shipping requirements needed for such building kits. In another example, customers may need additional assistance in order to unload such freight that carry the building kits; as such, additional time and labor is needed to simply receive and unload the building kits.

SUMMARY OF THE INVENTION

The presently disclosed pallet assemblies solve a need in providing a more compact packaging unit for delivering building kits. In one instance, the pallet assemblies discussed herein include support frames having an A-shaped configuration that stand and support building materials at an upright position for ease loading and unloading materials from the pallet assemblies. In another instance, the pallet assemblies discussed herein also include overall heights that support long and cumbersome materials for building kits while being under a predetermined height to prevent excessive shipping and freight charges. In yet another instance, the pallet assemblies discussed herein also provide the option of staging building materials of building kit in ways where the order of removing the building materials off of the pallet assemblies match with the steps of constructing the building from the building materials.

In one aspect, an exemplary embodiment of the present disclosure may provide a pallet assembly. The pallet assembly includes a base; a support frame operably engaged with the base; a first upright support of the support frame operably engaged with the base at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position; wherein the support frame has an A-shaped configuration.

In another aspect, an exemplary embodiment of the present disclosure may provide a pallet assembly. The pallet assembly includes a base; an A-frame operably engaged with the base; a first upright support of the A-frame operably engaged with the base at a first position defined at a first angle measured relative to the base; a second upright support of the A-frame operably engaged with the base at a second position opposite to the first position and defined at a second angle measured relative to the base; and a pair of cleats operably engaged with the base and spaced apart from the A-frame; wherein the second angle is greater than the first angle.

In another aspect, an exemplary embodiment of the present disclosure may provide a method of packaging a building kit to a pallet assembly, comprising: engaging a base of the pallet assembly with an A-frame of the pallet assembly loading a first set of building materials of the building kit the A-frame and onto the base; and loading a second set of building materials of the building kit onto the A-frame and onto the base of the pallet assembly, wherein the first set of building material is positioned between the A-frame and the second set of building material.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a pallet assembly. The pallet assembly includes a base; a support frame operably engaged with the base; a first upright support of the support frame operably engaged with the base at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position; wherein the support frame defines an A-shaped configuration.

This exemplary embodiment or another exemplary embodiment may further include a first angle measured between the first upright support and the base; and a second angle measured between the second upright support and the base; wherein the second angle is greater than the first angle. This exemplary embodiment or another exemplary embodiment may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. This exemplary embodiment or another exemplary embodiment may further include that the second angle measured between the second upright support and the base is approximately 85 degrees. This exemplary embodiment or another exemplary embodiment may further include a first length defined between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and a second length defined between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. This exemplary embodiment or another exemplary embodiment may further include that the first upright support is adapted to support building materials defining a length that is greater than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that the second upright support is adapted to support a building material defining a length that is less than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include a top end of the base that operably engages with the first end of the first upright support and the first end of the second upright support; a bottom end of the base opposite to the top end and adapted to interface with a ground surface; and an overall height defined between the first end of the first upright support and the bottom end; wherein the overall height is less than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that the overall height is less than 96 inches. This exemplary embodiment or another exemplary embodiment may further include that the first end of the first upright support operably engages with the base at the first position; and wherein the second end of the first upright support is positioned above and free from engaging with the second end of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that the first end of the second upright support operably engages with the base at the second position; and wherein the second end of the second upright support operably engages with the first upright support at a location between the first end of the first upright support and the second end of the first upright support. This exemplary embodiment or another exemplary embodiment may further include a storage compartment collectively defined by the base, the first upright support, and the second upright support. This exemplary embodiment or another exemplary embodiment may further include a pair of cleats operably engaged with the base and spaced apart from the support frame. This exemplary embodiment or another exemplary embodiment may further include a first distance measured between a first cleat of the pair of cleats and the first upright support; and a second distance measured between a second cleat of the pair of cleats and the second upright support; wherein the first distance is greater than the second distance. This exemplary embodiment or another exemplary embodiment may further include that the first cleat and the first upright support are adapted to support a first set of building materials; and wherein the second cleat and the second upright support are adapted to support a second set of building materials. This exemplary embodiment or another exemplary embodiment may further include a first pair of cross members of the first upright support operably engaging with a first pair of lateral upright supports; and a second pair of cross members of the second upright support operably engaging with a second pair of lateral upright supports. This exemplary embodiment or another exemplary embodiment may further include a first cross member of the first pair of cross members and a first cross member of the second pair of cross members are substantially aligned with one another; and wherein a second cross member of the first pair of cross members is positioned below a second cross member of the second pair of cross members. This exemplary embodiment or another exemplary embodiment may further include a first pair of lateral supports securing the first upright support and the second upright support with one another and being spaced apart from the base. This exemplary embodiment or another exemplary embodiment may further include a second pair of lateral supports securing the first upright support and the second upright support with one another and being secured to the base.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a pallet assembly. The pallet assembly includes a base; an A-frame operably engaged with the base; a first upright support of the A-frame operably engaged with the base at a first position defined at a first angle measured relative to the base; a second upright support of the A-frame operably engaged with the base at a second position opposite to the first position and defined at a second angle measured relative to the base; and a pair of cleats operably engaged with the base and spaced apart from the A-frame; wherein the second angle is greater than the first angle.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of packaging a building kit to a pallet assembly. The method includes steps of: engaging a base of the pallet assembly with an A-frame of the pallet assembly; loading a first set of building materials of the building kit the A-frame and onto the base; and loading a second set of building materials of the building kit onto the A-frame and onto the base of the pallet assembly, wherein the first set of building material is positioned between the A-frame and the second set of building material.

This exemplary embodiment or another exemplary embodiment may further include steps of supporting the first set of building material, by a first upright support of the A-frame, at a first angle measured between the first upright support and the base; and supporting the second set of building material, by a second upright support of the A-frame, at a second angle measured between the first upright support and the base; wherein the second angle is greater than the first angle. This exemplary embodiment or another exemplary embodiment may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. This exemplary embodiment or another exemplary embodiment may further include that the second angle measured between the second upright support and the base is approximately 85 degrees. This exemplary embodiment or another exemplary embodiment may further include steps of defining a first length of the first upright support measured between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and defining a second length of the second upright support measured between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. This exemplary embodiment or another exemplary embodiment may further include a step of supporting the first set of building material, by the first upright support, that defines a length that is greater than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include a step of supporting the second set of building material, by the second upright support, that defines a length that is less than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that the step of engaging the base with the A-frame further comprises: engaging a top end of the base with the first end of the first upright support and the first end of the second upright support; interfacing a bottom end of the base with a ground surface, wherein the bottom end is opposite to the top end; and defining an overall height between the first end of the second upright support and the bottom end; wherein the overall height is less than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that the overall height is less than 96 inches. This exemplary embodiment or another exemplary embodiment may further include that the step of engaging the base with the A-frame further comprises: engaging the first end of the first upright support with the base; and positioning the second end of the first upright support above the first end of the first upright support such that the second end of the first upright support is free from engaging with the first end of the second upright support. This exemplary embodiment or another exemplary embodiment may further include that the step of engaging the base with the A-frame further comprises: engaging the first end of the second upright support with the base; and engaging the second end of the second upright support with the first upright support at a location between the first end of the first upright support and the second end of the first upright support. This exemplary embodiment or another exemplary embodiment may further include a step of loading a third set of building materials inside of a storage compartment of the pallet assembly; wherein the storage compartment is collectively defined by the base, a first upright support of the A-frame, and the second upright support of the A-frame. This exemplary embodiment or another exemplary embodiment may further include a step of engaging a pair of cleats with the base and being spaced apart from the A-frame. This exemplary embodiment or another exemplary embodiment may further include steps of positioning a first cleat of the pair of cleats at a first distance measured from a first upright support of the A-frame; and positioning a second cleat of the pair of cleats at a second distance measured from a second upright support of the A-frame; wherein the first distance is greater than the second distance. This exemplary embodiment or another exemplary embodiment may further include steps of supporting the first set of building material on the first cleat and the first upright support; and supporting the second set of building material on the second cleat and the second upright support. This exemplary embodiment or another exemplary embodiment may further include steps engaging a first pair of cross members of a first upright support of the A-frame with a first pair of lateral upright supports; and engaging a second pair of cross members of a second upright support of the A-frame with a second pair of lateral upright supports. This exemplary embodiment or another exemplary embodiment may further include steps of aligning a first cross member of the first pair of cross members and a first cross member of the second pair of cross members with one another; and positioning a second cross member of the first pair of cross members is positioned below a second cross member of the second pair of cross members. This exemplary embodiment or another exemplary embodiment may further include a step of securing a first pair of lateral supports with a first upright support of the A-frame and a second upright support of the A-frame and being spaced apart from the base. This exemplary embodiment or another exemplary embodiment may further include a step of securing a second pair of lateral supports with the first upright support and the second upright support and being secured to the base.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of packaging a building kit to a pallet assembly. The method includes steps of: engaging a base of the pallet assembly with an A-frame of the pallet assembly; engaging a pair of cleats with the base and being spaced apart from the A-frame; loading a first set of building materials of the building kit onto the A-frame, the base, and a first cleat of the pair of cleats; loading a second set of building materials of the building kit onto the A-frame, the base, and a second cleat of the pair of cleats, wherein the first set of building material is positioned between the A-frame and the second set of building material; and loading a third set of building materials inside of a storage compartment of the pallet assembly.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of staging a building kit on a pallet assembly. The method includes steps of: engaging a base of the pallet assembly with a support frame of the pallet assembly, the support frame comprising: a first upright support of the support frame operably engaged with the base at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position; wherein the support frame has an A-shaped configuration; staging a building kit onto the pallet assembly in a preconfigured arrangement; effecting the building kit to be removed in a predetermined order of operations; and effecting a building to be constructed from the building kit based on the preconfigured arrangement.

This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises: supporting the building kit, by the support frame, along at least one plane of the support frame that is non-parallel to the base. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises: supporting a first set of building materials of the building kit, by the first upright support, along a first plane relative to the base; and supporting a second set of building materials of the building kit, by the second upright support, along a second plane relative to the base; wherein the first plane and the second plane are each non-parallel to the base. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a first set of building materials of the building kit onto the base and the support frame at a first position; and staging a second set of building materials of the building kit onto the base and the support frame at a second position opposite to the first position; wherein the first set of building materials and the second set of building materials are separated from one another by the support frame. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a third set of building materials inside of a storage compartment defined by the support frame and the base, collectively; wherein the third set of building materials is separated from the first set of building materials and the second set of building materials by the support frame. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting the first set of building materials to be removed from the support frame and the base at the first position in a first step of the predetermined order of operations; wherein the first set of building materials is adapted to build a first portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting the second set of building materials to be removed from the support frame and the base at the second position in a second step of the predetermined order of operations subsequent to the first step; wherein the second set of building materials is adapted to build a second portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting a third set of building materials of the building kit to be removed from the support frame and the base at a third position in a third step of the predetermined order of operations subsequent to the first step and the second step; wherein the third set of building materials is adapted to build a third portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a first set of building materials of the building kit onto the base and the support frame; and staging a second set of building materials of the building kit onto the base and the support frame; wherein the second set of building materials is supported by the first set of building materials on the support frame. This exemplary embodiment or another exemplary embodiment may further include the step of staging the building kit onto the pallet assembly further comprises: staging a third set of building materials inside of a storage compartment defined by the support frame and the base, collectively; wherein the third set of building materials is separated from the first set of building materials and the second set of building materials by the support frame. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting the second set of building materials to be removed from the support frame and the base in a first step of the predetermined order of operations; and wherein the first set of building materials is adapted to build a first portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting the first set of building materials to be removed from the support frame and the base in a second step of the predetermined order of operations subsequent to the first step; wherein the second set of building materials is adapted to build a second portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of effecting the building kit to be removed further comprises: effecting a third set of building materials of the building kit to be removed from the support frame and the base in a third step of the predetermined order of operations subsequent to the first step and the second step; wherein the third set of building materials is adapted to build a third portion of the building kit. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprising: supporting the building kit with a pair of cleats on the base, wherein the pair of cleats is spaced apart from the first upright support and the second upright support. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprising: supporting a first set of building materials of the building kit with a first cleat on the base, wherein the first cleat is spaced apart from the first upright support; and supporting a second set of building materials of the building kit with a second cleat on the base, wherein the second cleat is spaced apart from the second upright support. This exemplary embodiment or another exemplary embodiment may further include that the step of staging the building kit onto the pallet assembly further comprises that a total height measured between the pallet assembly and the building kit is less than or equal to eight feet. This exemplary embodiment or another exemplary embodiment may further include steps of supporting a first set of building materials of the building kit, by the first upright support, at a first angle measured between the first upright support and the base; and supporting a second set of building materials of the building kit, by the second upright support, at a second angle measured between the first upright support and the base; and wherein the second angle is greater than the first angle. This exemplary embodiment or another exemplary embodiment may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. This exemplary embodiment or another exemplary embodiment may further include that the second angle measured between the second upright support and the base is approximately 85 degrees.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of staging a building kit on a pallet assembly. The method includes steps of: engaging a base of the pallet assembly with a support frame of the pallet assembly, the support frame comprising: a first upright support of the support frame operably engaged with the base at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position; wherein the support frame has an A-shaped configuration; staging the building kit onto the first upright support and the second upright support simultaneously in a preconfigured arrangement; effecting the building kit to be removed in a predetermined order of operations; and effecting a building to be constructed from the building kit based on the predetermined order of operations.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a pallet assembly. The pallet assembly includes a base; a first upright support of a support frame operably engaged with the base at a first position, wherein the first upright support is adapted to support a first set of pre-cut materials for a building at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position, wherein the second upright support is adapted to support a second set of pre-cut material for the building at a second position; wherein the support frame defines an asymmetrical A-shaped configuration.

This exemplary embodiment or another exemplary embodiment may further include a first length defined between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and a second length defined between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. This exemplary embodiment or another exemplary embodiment may further include that each pre-cut material of the first set of pre-cut materials defines a length that is equal to or greater than the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include that each pre-cut material of the first set of pre-cut materials defines a length that is equal to or less than the second length of the second upright support. This exemplary embodiment or another exemplary embodiment may further include that one of the first upright support and the second upright support lies along at least one plane for supporting one of the first set of pre-cut materials and the second set of pre-cut materials; wherein the at least one plane is non-parallel to the base. This exemplary embodiment or another exemplary embodiment may further include a first plane defined along the first upright support; and a second plane defined along the second upright support; wherein the first plane and the second plane are each non-parallel to the base. This exemplary embodiment or another exemplary embodiment may further include that the first plane and the second plane intersect with one another. This exemplary embodiment or another exemplary embodiment may further include a storage compartment collectively defined by the base, the first upright support, and the second upright support; wherein the storage compartment is adapted to support a set of fasteners of the building. This exemplary embodiment or another exemplary embodiment may further include a first angle measured between the first upright support and the base; and a second angle measured between the second upright support and the base; wherein the second angle is greater than the first angle. This exemplary embodiment or another exemplary embodiment may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. This exemplary embodiment or another exemplary embodiment may further include that the second angle measured between the second upright support and the base is approximately 85 degrees. This exemplary embodiment or another exemplary embodiment may further include a pair of cleats operably engaged with the base and spaced apart from the support frame. This exemplary embodiment or another exemplary embodiment may further include that the first cleat and the first upright support are adapted to support the first set of pre-cut material; and wherein the second cleat and the second upright support are adapted to support the second set of pre-cut material. This exemplary embodiment or another exemplary embodiment may further include a total height measured between the pallet assembly and the first set of pre-cut materials is less than or equal to eight feet.

In yet another aspect, an exemplary embodiment of the present disclosure may provide a method of packaging at least one set of pre-cut materials on a pallet assembly. The method includes steps of: engaging a base of the pallet assembly with an A-frame of the pallet assembly; loading a first set of pre-cut materials of the building kit the A-frame and onto the base; loading a second set of pre-cut materials of the building kit onto the A-frame and onto the base of the pallet assembly; supporting the first set of pre-cut materials at a first upright position by the A-frame; and supporting the second set of pre-cut materials at a second upright position by the A-frame.

This exemplary embodiment or another exemplary embodiment may further include that the steps of supporting the first set of pre-cut materials and the second set of pre-cut materials further comprises: supporting the first set of pre-cut materials, by a first upright support of the A-frame, at a first angle measured between the first upright support and the base; and supporting the second set of pre-cut materials, by a second upright support of the A-frame, at a second angle measured between the first upright support and the base; wherein the second angle is greater than the first angle. This exemplary embodiment or another exemplary embodiment may further include that the first angle measured between the first upright support and the base is approximately 70 degrees; and wherein the second angle measured between the second upright support and the base is approximately 85 degrees. This exemplary embodiment or another exemplary embodiment may further include steps of defining a first length of a first upright support of the A-frame measured between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and defining a second length of a second upright support of the A-frame measured between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. This exemplary embodiment or another exemplary embodiment may further include a step of supporting the first set of pre-cut materials, by the first upright support, that defines a length that is greater than or equal to the first length of the first upright support. This exemplary embodiment or another exemplary embodiment may further include a step of supporting the second set of pre-cut materials, by the second upright support, that defines a length that is less than or equal to the second length of the second upright support.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more exemplary embodiment(s) of the present disclosure is set forth in the following description, is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended claims. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate various example configurations and methods, and other example embodiments of various aspects of the invention. It will be appreciated that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. One of ordinary skill in the art will appreciate that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of another element may be implemented as an external component and vice versa. Furthermore, elements may not be drawn to scale.

FIG. 1 (FIG. 1) is a top, rear, second side isometric perspective view of a pallet assembly in accordance with one aspect of the present disclosure, wherein the pallet assembly is supporting building materials of a building kit.

FIG. 2 (FIG. 2) is a top, rear, second side isometric perspective view of the pallet assembly shown in FIG. 1.

FIG. 3 (FIG. 3) is a first side elevation view of the pallet assembly shown in FIG. 1.

FIG. 4 (FIG. 4) is a front elevation view of the pallet assembly shown in FIG. 1.

FIG. 5 (FIG. 5) is a top, front, first side isometric perspective view of a pallet assembly in accordance with another aspect of the present disclosure, wherein the pallet assembly is supporting building materials of another building kit.

FIG. 6 (FIG. 6) is a top, front, first side isometric perspective view of the pallet assembly shown in FIG. 5.

FIG. 7 (FIG. 7) is a first side elevation view of the pallet assembly shown in FIG. 5.

FIG. 8 (FIG. 8) is a rear elevation view of the pallet assembly shown in FIG. 5.

FIG. 9A (FIG. 9A) is an operational view of the pallet assembly shown in FIG. 5, wherein a first set of building material is introduced to and supported by a base of the pallet assembly and a first upright support of a support frame of the pallet assembly.

FIG. 9B (FIG. 9B) is another operational view of the pallet assembly continuing from FIG. 9A, wherein a second set of building material is introduced to and supported by the base of the pallet assembly and a second upright support of the support frame of the pallet assembly.

FIG. 9C (FIG. 9C) is another operational view of the pallet assembly continuing from FIG. 9B, wherein a third set of building material is introduced to and supported by the base of the pallet assembly and housed inside of the support frame of the pallet assembly.

FIG. 10A (FIG. 10A) is an operational view of the pallet assembly loaded with the building material, wherein a pallet jack is being introduced to the pallet assembly.

FIG. 10B (FIG. 10B) is another operational view continuing from FIG. 10A, wherein the pallet assembly is loaded onto a liftgate of a vehicle by the pallet jack.

FIG. 10C (FIG. 10C) is another operational view continuing from FIG. 10A, wherein the pallet assembly and pallet jack are lifted into the vehicle by the liftgate.

FIG. 11 (FIG. 11) is an operational view showing a user removing the first set of building material from the pallet assembly in a first stage to form a first section of a building.

FIG. 12 (FIG. 12) is another operational view continuing from FIG. 11, wherein the user is removing the second set of building material from the pallet assembly in a second stage to form a second section of the building.

FIG. 13 (FIG. 13) is another operational view continuing from FIG. 12, wherein the user is removing the third set of building material from the pallet assembly in a third stage to form a third section of the building.

FIG. 14 (FIG. 14) is a flowchart of installation instructions for removing building materials from one of the pallet assemblies discussed herein.

FIG. 15 (FIG. 15) is a flowchart for a method of packaging a building kit to a pallet assembly.

FIG. 16 (FIG. 16) is another flowchart for a method of staging a building kit on a pallet assembly.

FIG. 17 (FIG. 17) is another flowchart for a method of packaging at least one set of pre-cut materials on a pallet assembly.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

FIGS. 1-4 illustrate a pallet assembly 1 in accordance with one aspect of the present disclosure. As discussed in greater detail below, pallet assembly 1 is configured to support a building kit or similar kits for packaging and transporting the building kit.

Pallet assembly 1 includes a base or pallet 10 that is configured to support additional components of pallet assembly 1 and building materials of a building kit. As best seen in FIGS. 2 and 3, base 10 includes a first end 10a, a second end 10b longitudinally opposite to the first end 10a, and a longitudinal axis defined between the first end 10a and the second end 10b. Base 10 also includes a first side 10c, a second side 10d transversely opposite to the first side 10c, and a transverse axis defined between the first side 10c and the second side 10d. Base 10 also includes a top end 10e, a bottom end 10f vertically opposite to the top end 10e, and a vertical axis defined between the top end 10e and the bottom end 10f. While not illustrated herein, base 10 may also include a platform or sheet of material that extends along the entire length of the top end 10e. Such inclusion of a platform along the top end 10e of the base 10 may provide a continuous, uninterrupted surface that allows for ease of attaching a support frame to the base 10 and/or resting building material on the base 10.

Base 10 also includes various dimensions and/or parameters. As best seen in FIG. 3, base 10 defines a length that is measured between the first end 10a and the second end 10b; such length is denoted by a double arrow labeled “L” in FIG. 2. In one example, length “L” of base 10 may be approximately 60 inches. Still referring to FIG. 3, base 10 also defines a height that is measured between the top end 10e and the bottom end 10f; such height is denoted by a double arrow labeled “H1” in FIG. 2. In one example, height “H1” of base 10 may be approximately five and three-quarter inches. Referring to FIG. 3, base 10 also defines a width that is measured between the first side 10c and the second side 10d; such width is denoted by a double arrow labeled “W” in FIG. 3. In one example, width “W” of base 10 may be approximately 49 inches.

Pallet assembly 1 also includes a pair of cleats 12. As best seen in FIGS. 2-3, a first cleat 12a of the pair of cleats 12 operably engages with the base 10 at the first end 10a and extends upwardly from the top end 10e of the base 10 along an axis that is parallel to the vertical axis of the base 10. Similarly, a second cleat 12b of the pair of cleats 12 operably engages with the base 10 at the second end 10b and extends upwardly from the top end 10e of the base 10 along an axis that is parallel to the vertical axis of the base 10. In the present disclosure, the second cleat 12b of the pair of cleats 12 is positioned longitudinally opposite to the first cleat 12a of the pair of cleats 12 relative to the longitudinal axis of base 10. Additionally, each cleat of the pair of cleats 12 is also positioned between the first side 10c and the second side 10d of the base 10 in which each cleat of the pair of cleats 12 may define a length that is less than or equal to the width “W” of base 10. As discussed in greater detail below, the pair of cleats 12 is configured to support and maintain one or more building materials of a building kit on the base 10 to prevent the building materials from shifting or sliding off of the base 10 at the first end 10a or at the second end 10b during loading or transportation operations.

It should be understood that base 10 may be a pallet or substantially similar support unit that is commercially used in packaging, freight, and/or logistics operations for transporting building kits and other building materials of the like.

Pallet assembly 1 also includes a support frame 20 that operably engages with the base 10. As best seen in FIG. 1, support frame 20 operably engages with the base 10 at the top end 10e. The components and elements of support frame 20 are now discussed in greater detail below.

Support frame 20 includes a first upright support 22 that operably engages with the base 10 at a first position. As best seen in FIG. 3, first upright support 22 includes a top end 22a that is spaced apart from the base 10, and a bottom end 22b that is opposite to the top end 22a and operably engages with the base 10 at the top end 10e. First upright support 22 also defines a first length 22c that is measured between the top end 22a and the bottom end 22b (see FIG. 3). In one exemplary embodiment, the first length 22c of the first upright support 22 may be approximately 72 inches.

In this embodiment, the first upright support 22 is formed by a pair of boards or elongated members. With such configuration, each board of the pair of boards makes up the top end 22a, the bottom end 22b, and the first length 22c. First upright support 22 also includes a pair of cross members 22d-1, 22d-2 that operably engages the pair of boards with one another. As best seen in FIGS. 2 and 4, first upright support 22 includes a first cross member 22d-1 that operably engages with the pair of boards at the top end 22a of the first upright support 22. The first upright support 22 also includes a second cross member 22d-2 that operably engages with the pair of boards at a location medial to the top end 22a of the first upright support 22 and the bottom end 22b of the first upright support 22; the second cross member 22d-2 is positioned vertically below the first cross member 22d-1. With such inclusion of the pair of cross members 22d-1, 22d-2, the pair of cross members 22d-1, 22d-2 provides axial support and/or lateral support to the pair of boards that forms the first upright support 22 to prevent sheering along an axis that is parallel to the transverse axis of the base 10.

In this embodiment, the first upright support upright 22 also includes an exterior or first support surface 22e and an interior or second support surface 22f. As best seen in FIG. 3, the exterior surface 22e extends along the entire length of the first upright support upright 22 from the top end 22a to the bottom end 22b. The exterior surface 22e also faces away from the base 10 and towards the exterior environment surrounding the pallet assembly 1. In operation, the exterior surface 22e is configured to support one or more sets of building materials along with the base 10 and the first cleat 12a. Still referring to FIG. 3, the interior surface 22f also extends along the entire length of the first upright support upright 22 from the top end 22a to the bottom end 22b. The interior surface 22f also faces towards the base 10 and away from the exterior environment surrounding the pallet assembly 1; as such, the interior surface 22f faces in an opposing direction as compared to the exterior surface 22e. In operation, the interior surface 22f may support building materials inside of the support frame 20, which is discussed in greater detail below.

In this embodiment, the first upright support upright 22 is engaged with the base 10 at a first angle measured relative to the top end 10e of base 10; such first angle is represented by double arrows labeled “A1” in FIG. 3. In one exemplary embodiment, the first angle may be approximately 75 degrees measured between the first upright support upright 22 (particularly the interior surface 22f) and the top end 10e of the base 10.

Support frame 20 also includes a second upright support 24 that operably engages with the base 10 at a second position opposite to the first position of first upright support 22. As best seen in FIG. 3, second upright support 24 includes a top end 24a that is spaced apart from the base 10, and a bottom end 24b that is opposite to the top end 24a and operably engages with the base 10 at the top end 10e. Second upright support 24 also defines a second length 24c that is measured between the top end 24a and the bottom end 24b. In this embodiment, the second length 24c of the second upright support 24 and the first length 22c of the first upright support 22 are equal to one another. In one exemplary embodiment, the second length 24c of the second upright support 24 may be approximately 72 inches.

In this embodiment, the second upright support 24 is formed by a pair of boards or elongated members similar to the first upright support 22. With such configuration, each board of the pair of boards makes up the top end 24a, the bottom end 24b, and the second length 24c. Second upright support 24 also includes a pair of cross members 24d-1, 24d-2 that operably engages the pair of boards with one another. As best seen in FIG. 2, second upright support 24 includes a first cross member 24d-1 that operably engages with the pair of boards at the top end 24a of the second upright support 24. The second upright support 24 also includes a second cross member 24d-2 that operably engages with the pair of boards at a location medial to the top end 24a of the second upright support 24 and the bottom end 24b of the second upright support 24; the second cross member 24d-2 is positioned vertically below the first cross member 24d-1. With such inclusion of the pair of cross members 24d-1, 24d-2, the pair of cross members 24d-1, 24d-2 provides axial support and/or lateral support to the pair of boards that forms the second upright support 24 to prevent sheering along an axis that is parallel to the transverse axis of the base 10.

In this embodiment, the second upright support upright 24 also includes an exterior or first support surface 24e and an interior or second support surface 24f. As best seen in FIG. 3, the exterior surface 24e extends along the entire length of the second upright support upright 24 from the top end 24a to the bottom end 24b. The exterior surface 24e also faces away from the base 10 and towards the exterior environment surrounding the pallet assembly 1. In operation, the exterior surface 24e is configured to support one or more sets of building materials along with the base 10 and the second cleat 12b. Still referring to FIG. 3, the interior surface 24f also extends along the entire length of the second upright support upright 24 from the top end 24a to the bottom end 24b. The interior surface 24f also faces towards the base 10 and away from the exterior environment surrounding the pallet assembly 1; as such, the interior surface 24f faces in an opposing direction as compared to the exterior surface 24e. In operation, the interior surface 24f may support building materials inside of the support frame 20, which is discussed in greater detail below.

In this embodiment, the second upright support 24 is engaged with the base 10 at a second angle measured relative to the top end 10e of base 10; such second angle is represented by double arrows labeled “B1” in FIG. 2. In this embodiment, the first angle of the first upright support 22 and the second angle of the second upright support 24 are equal to one another. In one exemplary embodiment, the second angle may be approximately 75 degrees measured between the second upright support upright 24 (particularly the interior surface 24f) and the top end 10e of the base 10.

In this embodiment, the top end 22a of the first upright support 22 operably engages with the top end 24a of the second upright support 24 to form a A-shape configuration when viewed from a side elevation (see FIG. 3). In this embodiment, the first angle A1 and the second angle B1 are equal to one another to form a symmetrical A-shape configuration. The A-shape configuration of the support frame 20 is considered advantageous at least because one or more sets of building materials of a building kit may be compactly stacked and packaged onto the support frame 20 and the base 10 (see FIG. 1). Additionally, the A-shape configuration of the support frame 20 is considered advantageous at least because building materials may be supported at an upright orientation and/or standing position that allows for ease of loading material onto the pallet assembly 1 and unloading material from the pallet assembly 1.

Support frame 20 also includes a pair of lateral supports 26a, 26b that operably engages with the first upright support 22 and the second upright support 24. More particularly, and as best seen in FIGS. 2-3, the pair of lateral supports 26a, 26b operably engages with the bottom ends 22b, 24b of the first upright support 22 and the second upright support 24. Specifically, a first lateral support 26a operably engages with a first board of the pair of boards of the first upright support 22 at the bottom end 22b and with a first board of the pair of boards of the second upright support 24 at the bottom end 24b. Similarly, a second lateral support 26b operably engages with a second board of the pair of boards of the first upright support 22 at the bottom end 22b and with a second board of the pair of boards of the second upright support 24 at the bottom end 24b. With such inclusion of the pair of lateral supports 26a, 26b, pair of lateral supports 26a, 26b provides axial support to the pair of boards that forms the first and second upright supports 22, 24 to prevent sheering or shifting along longitudinal axes of the first upright support 22 and the second upright support 24 at the bottom ends 22b, 24b.

The first and second upright supports 22, 24 each lie on a plane that is non-parallel to the base 10. As best seen in FIG. 3, the first upright support 22 lies on a first plane 28a at the first angle “A1”, and the second upright support 24 lies on a second plane 28b at the second angle “B1”. With such structural arrangement, packers are enabled to load and stack building materials at an upright position that will reduce potential lifting injures as well as reduce the act of loading material onto the pallet assembly 1.

In this embodiment, the support frame 20 is spaced apart from the pair of cleats 12a, 12b at a desired distance. As best seen in FIG. 3, a first distance is measured between the first cleat 12a and the bottom end 22b of the first upright support 22; such first distance is denoted by double arrows labeled “D1” in FIG. 3. Similarly, a second distance is measured between the second cleat 12b and the bottom end 24b of the second upright support 24; such second distance is denoted by double arrows labeled “D2” in FIG. 3. In this embodiment, the first distance “D1” and the second distance “D2” are equal to one another.

Support frame 20 also defines a central space or storage compartment 30 among the base 10, the first upright support 22, and the second upright support 24. More particularly, and as best seen in FIGS. 2 and 3, the storage compartment 30 is defined among the top end 10e of the base 10, the interior surface 22f of the first upright support 22, and the interior surface 24f of the second upright support 24. In the storage compartment 30, additional building materials that may be fragile or small in size (such as windows, fasteners, connectors, etc.) may be stored inside of storage compartment 30 for easy access when unloading the building materials of the building kit. As such, one or more of the top end 10e of the base 10, the interior surface 22f of the first upright support 22, and the interior surface 24f of the second upright support 24 may support such building materials inside of the storage compartment 30 while larger building material is supported by the one or more of the top end 10e of the base 10, the exterior surface 22e of the first upright support 22, and the exterior surface 24e of the second upright support 24.

Support frame 20 also includes various dimensions and/or parameters. As best seen in FIG. 3, support frame 20 defines a height that is measured between the base 10 to the top ends 22a, 24a of the first and second upright supports 22, 24; such height is denoted by a double arrow labeled “H2” in FIG. 2. It should be noted a desired maximum height measured between the bottom end 10f of base 10 and a top end of a building material is approximately 96 inches for transporting; such overall height is denoted by a double arrow labeled “H” in FIG. 4.

As best seen in FIG. 1, a packer may stack a first set of building materials 40a of a building kit 40 onto the base 10 and the support frame 20. While the first set of building materials 40a is stacked on both the first upright support 22 and the second upright support 26, it is contemplated that the first set of building materials 30a may also rest on one of the first upright support 22 and the second upright support 24 if desired. Subsequently, the packer may then stack a second set of building materials 40b of the building kit 40 onto the first set of building materials 40a in which the base 10 and the support frame 20 now collectively hold the first set of building materials 40a and the second set of building materials 40b. Further, the second set of building materials 30b may also engage with the pair of cleats 12a, 12b of the base 10 to prevent lower or bottom ends of the building materials of the second set of building materials 40b from shifting or sliding off of the base 10 during transportation. Lastly, the packer may then stack a third set of building materials 40c of the building kit 40 inside of storage compartment 30 where the third set of building materials 40c may be fragile or small in size.

Such packaging arrangement and capabilities of the pallet assembly 1 may ease steps of constructing the building kit 40. Particularly, the arrangement of the building materials 40a, 40b, 40c on the pallet assembly 1 may be organized in such a way where the second set of building materials 30b is removed from the pallet assembly 1 first to begin the building process of building kit 40 while the first set of building materials 40a is removed from the pallet assembly 1 subsequent to the second set of building materials 40b for construction needs.

FIGS. 5-8 illustrate another pallet assembly 100. As discussed in greater detail below, pallet assembly 100 is configured to support a building kit or similar kits for packaging and transporting the building kit similar to pallet assembly 10, except as detailed below.

Pallet assembly 100 includes a base or pallet 110 that is configured to support additional components of pallet assembly 1 and building materials of a building kit. It should be noted that base 110 is similar to base 10 of the pallet assembly 1 discussed above. Specifically, base 110 includes a first end 110a, a second end 110b, a first side 110c, a second side 110d, a top end 110e, a bottom end 110f, a length “L” measured between first end 110a and second end 110b, a height “H1” measured between top end 110e and bottom end 110f, and a width “W” measured between first side 110c and second side 110d that are substantially similar to the first end 10a, the second end 10b, the first side 10c, the second side 10d, the top end 10e, the bottom end 10f, the length “L”, the height “H1”, and the width “W” of the base 10 discussed previously.

However, in this embodiment, base 110 includes a platform 110g that extends along the entire length of the top end 110e. Such inclusion of the platform 110g along the top end 110e of the base 110 provides a continuous, uninterrupted surface that allows for ease of attaching a support frame to the base 10 and/or resting building material on the base 10. As discussed previously, platform 110g may be added to base 10 of pallet assembly 1 if desired by users of pallet assembly 1.

Pallet assembly 1 also includes a pair of cleats 112a, 112b. As best seen in FIGS. 5-6, a first cleat 112a of the pair of cleats operably engages with the platform 110g at the first end 110a and extends upwardly from the platform 110g along an axis that is parallel to the vertical axis of the base 110. Similarly, a second cleat 112b of the pair of cleats operably engages with the platform 110g at the second end 110b and extends upwardly from the platform 110g along an axis that is parallel to the vertical axis of the base 110. In the present disclosure, the second cleat of the pair of cleats 112b is positioned longitudinally opposite to the first cleat 112a of the pair of cleats relative to a longitudinal axis of base 110 that extends between the first end 110a and the second end 110b. Additionally, each cleat of the pair of cleats 112a, 112b is also positioned between the first side 110c and the second side 110d of the base 10 in which each cleat of the pair of cleats 112a, 112b may define a length that is less than or equal to the width “W” of base 10. Similar to the pair of cleats 12a, 12b, the pair of cleats 112a, 112b is configured to support and maintain one or more building materials of a building kit on the base 110 to prevent the building materials from shifting or sliding off of the base 110 at the first end 110a or at the second end 110b.

It should be understood that base 110 may be a pallet or substantially similar support unit that is commercially used in packaging, freight, and/or logistic operations for transporting building kits and other building materials of the like.

Pallet assembly 100 also includes a support frame 120 that operably engages with the base 110. As best seen in FIG. 5, support frame 210 operably engages with the base 110 at the top end 110e and/or platform 110g. The components and elements of support frame 120 are now discussed in greater detail below.

Support frame 120 includes a first upright support 122 that operably engages with the base 110 at a first position. As best seen in FIG. 7, first upright support 122 includes a top end 122a that is spaced apart from the base 110, and a bottom end 122b that is opposite to the top end 122a and operably engages with the base 110 at the top end 110e and/or platform 110g. First upright support 122 also defines a first length 122c that is measured between the top end 122a and the bottom end 122b. In one exemplary embodiment, the first length 122c of the first upright support 122 may be approximately 95 inches.

Similar to the first upright support 22, the first upright support 122 is also formed by a pair of boards or elongated members. With such configuration, each board of the pair of boards makes up the top end 122a, the bottom end 122b, and the first length 122c. First upright support 122 also includes a pair of cross members 122d-1, 122d-2 that operably engages the pair of boards with one another. As best seen in FIGS. 6 and 8, first upright support 122 includes a first cross member 122d-1 that operably engages with the pair of boards at the top end 122a of the first upright support 122. The first upright support 122 also includes a second cross member 122d-2 that operably engages with the pair of boards at a location medial to the top end 122a of the first upright support 122 and the bottom end 122b of the first upright support 122; the second cross member 122d-2 is positioned vertically below the first cross member 122d-1. With such inclusion of the pair of cross members 122d-1, 122d-2, the pair of cross members 122d-1, 122d-2 provides axial support and/or lateral support to the pair of boards that forms the first upright support 122 to prevent sheering along an axis that is parallel to a transverse axis of base 110 defined between the first and second sides 110c, 110d.

In this embodiment, the first upright support upright 122 also includes an exterior or first support surface 122e and an interior or second support surface 122f. As best seen in FIG. 7, the exterior surface 122e extends along the entire length of the first upright support upright 122 from the top end 122a to the bottom end 122b. The exterior surface 122e also faces away from the base 110 and towards the exterior environment surrounding the pallet assembly 100. In operation, the exterior surface 122e is configured to support one or more sets of building materials along with the base 110 and the first cleat 112a. Still referring to FIG. 7, the interior surface 122f also extends along the entire length of the first upright support upright 122 from the top end 122a to the bottom end 122b. The interior surface 122f also faces towards the base 110 and away from the exterior environment surrounding the pallet assembly 100; as such, the interior surface 122f faces in an opposing direction as compared to the exterior surface 122e. In operation, the interior surface 122f is configured to support building materials inside of the support frame 120, which is discussed in greater detail below.

In this embodiment, the first upright support upright 122 is engaged with the base 110 at a first angle measured relative to the top end 110e and/or platform 110g of base 110; such first angle is represented by double arrows labeled “A2” in FIG. 6. In one exemplary embodiment, the first angle A2 may be between 45 degrees up to about 70 degrees measured between the first upright support upright 122 (particularly the interior surface 122f) and the platform 110g of the base 110. In another exemplary embodiment, the first angle A2 may be approximately 70 degrees measured between the first upright support upright 122 (particularly the interior surface 122f) and the platform 110g of the base 110.

Support frame 120 also includes a second upright support 124 that operably engages with the base 110 at a second position opposite to the first position of first upright support 122. As best seen in FIG. 7, second upright support 124 includes a top end 124a that is spaced apart from the base 110, and a bottom end 124b that is opposite to the top end 124a and operably engages with the base 110 at the top end 110e and/or platform 110g. Second upright support 124 also defines a second length 124c that is measured between the top end 124a and the bottom end 124b. In this embodiment, the second length 124c of the second upright support 124 is less the first length 122c of the first upright support 122. In one exemplary embodiment, the second length 124c of the second upright support 124 may be approximately 72 inches.

In this embodiment, the second upright support 124 is formed by a pair of boards or elongated members similar to the first upright support 122. With such configuration, each board of the pair of boards makes up the top end 124a, the bottom end 124b, and the second length 124c. Second upright support 124 also includes a pair of cross members 124d-1, 124d-2 that operably engages the pair of boards with one another. As best seen in FIGS. 6 and 8, second upright support 124 includes a first cross member 124d-1 that operably engages with the pair of boards at the top end 124a of the second upright support 124. The second upright support 124 also includes a second cross member 124d-2 that operably engages with the pair of boards at a location medial to the top end 124a of the second upright support 124 and the bottom end 124b of the second upright support 124; the second cross member 124d-2 is positioned vertically below the first cross member 124d-1. With such inclusion of the pair of cross members 124d-1, 124d-2, the pair of cross members 124d-1, 124d-2 provides axial support and/or lateral support to the pair of boards that forms the second upright support 124 to prevent sheering along an axis that is parallel to the transverse axis of base 110.

In this embodiment, the second upright support upright 124 also includes an exterior or first support surface 124e and an interior or second support surface 124f. As best seen in FIG. 7, the exterior surface 124e extends along the entire length of the second upright support upright 124 from the top end 124a to the bottom end 124b. The exterior surface 124e also faces away from the base 110 into the exterior environment surrounding the pallet assembly 100. In operation, the exterior surface 124e is configured to support one or more sets of building materials along with the base 110 and the second cleat 112b. Still referring to FIG. 7, the interior surface 124f also extends along the entire length of the second upright support upright 124 from the top end 124a to the bottom end 124b. The interior surface 124f also faces towards the base 110 and away from the exterior environment surrounding the pallet assembly 100; as such, the interior surface 124f faces in an opposing direction as compared to the exterior surface 124e. In operation, the interior surface 124f is configured to support building materials inside of the support frame 120, which is discussed in greater detail below.

In this embodiment, the second upright support 124 is engaged with the base 110 at a second angle measured relative to the top end 10e and/or platform 110g of base 110; such second angle is represented by double arrows labeled “B2” in FIG. 6. In this embodiment, the second angle B2 of the second upright support 124 is greater than first angle A2 of the first upright support 122. In one exemplary embodiment, the second angle B2 may be between 60 degrees up to about 85 degrees measured between the second upright support upright 124 (particularly the interior surface 124f) and the platform 110g of the base 110. In another exemplary embodiment, the second angle B2 may be approximately 85 degrees measured between the second upright support upright 124 (particularly the interior surface 124f) and the platform 110g of the base 110. In another exemplary embodiment, the second angle B2 may be approximately 80 degrees measured between the second upright support upright 124 (particularly the interior surface 124f) and the platform 110g of the base 110.

In this embodiment, the top end 122a of the first upright support 122 operably engages with the top end 124a of the second upright support 124 to form a A-shape configuration when viewed from a side elevation (see FIG. 6). In this embodiment, however, the first angle A2 of the first upright support 122 and the second angle B2 of the second upright support 124 are different angles and thus form an asymmetrical A-shape configuration. Such A-shape configuration of the support frame 120 is considered advantageous at least because one or more sets of building materials of a building kit may be compactly stacked and packaged onto the support frame1 20 and the base 110 (see FIG. 5). Additionally, the A-shape configuration of the support frame 120 is considered advantageous at least because building materials may be supported at an upright orientation and/or standing position that allows for ease of loading material onto the pallet assembly 100 and unloading material from the pallet assembly 100. Furthermore, with such asymmetrical A-shape configuration, users of pallet assembly 100 may desire this configuration of the pallet assembly 100 to stack and support piece of building material on the first upright support 122 that are approximately eight feet in length (e.g., standard lengths of lumber and other building materials commonly used in the building and constructions fields). Additionally, users of pallet assembly 100 may desire this configuration of the pallet assembly 100 on the second upright support 124 to stack and support piece of building material that are less than eight feet in length.

Support frame 120 also includes pairs of lateral supports 126a, 126b that operably engages with the first upright support 122 and the second upright support 124. More particularly, and as best seen in FIGS. 6 and 8, a first or lower pair of lateral supports 126a operably engages with the bottom ends 122b, 124b of the first upright support 122 and the second upright support 124. Specifically, the lower pair of lateral supports 126a operably engages with the pair of boards of the first upright support 122 at the bottom end 122b and with the pair of boards of the second upright support 124 at the bottom end 124b. The lateral supports of the lower pair of lateral supports 126a are also aligned with one another along an axis that is orthogonal to longitudinal axes of the first and second upright supports 122, 124. Similarly, a second or upper pair of lateral supports 126b operably engages with the pair of boards of the first upright support 122 at a location between the first end 122a and the second end 122b and with the pair of boards of the second upright support 124 at a location between the first end 124a and the second end 124b. The lateral supports of the upper pair of lateral supports 126b are also aligned with one another along an axis that is orthogonal to longitudinal axes of the first and second upright supports 122, 124. With such inclusion of the pairs of lateral supports 126a, 126b, the pairs of lateral supports 126a, 126b provides longitudinal axial support to the pair of boards that forms the first and second upright supports 122, 124 to prevent sheering or shifting along a longitudinal axes of the first upright support 122 and the second upright support 124 at the bottom ends 122b, 124b.

The first and second upright supports 122, 124 each lie on a plane that is non-parallel to the base 10. As best seen in FIG. 7, the first upright support 22 lies on a first plane 128a at the first angle “A1”, and the second upright support 124 lies on a second plane 128b at the second angle “B1”. With such structural arrangement, packers are enabled to load and stack building materials at an upright position that will reduce potential lifting injures as well as reduce the act of loading material onto the pallet assembly 100.

In this embodiment, the support frame 120 is spaced apart from the pair of cleats 112a, 112b at a desired distance. As best seen in FIG. 3, a first distance is measured between the first cleat 112a and the bottom end 122b of the first upright support 122; such first distance is denoted by double arrows labeled “D1” in FIG. 7. Similarly, a second distance is measured between the second cleat 112b and the bottom end 124b of the second upright support 124; such second distance is denoted by double arrows labeled “D2” in FIG. 7. In this embodiment, the first distance “D1” is greater than the second distance “D2”. In other exemplary embodiments, any suitable distance may be defined between first cleat 112a and first upright support 122 and between second cleat 112b and second upright support 124. In one exemplary embodiment, the first distance “D1” and the second distance “D2” are equal to one another. In another exemplary embodiment, the first distance “D1” is less than the second distance “D2”.

Support frame 120 also defines a central space or storage compartment 130 among the base 110, the first upright support 122, and the second upright support 124. More particularly, and as best seen in FIGS. 6 and 7, the storage compartment 130 is defined among the platform 110g of the base 110, the interior surface 122f of the first upright support 122, and the interior surface 124f of the second upright support 124. In the storage compartment 130, additional building materials (such as windows, fasteners, connectors, etc.) may be stored inside of storage compartment 130 for easy access when unloading the building materials of the building kit. As such, one or more of the platform 110g of the base 110, the interior surface 122f of the first upright support 122, and the interior surface 124f of the second upright support 124 may support such building materials inside of the storage compartment 130 while larger building material is supported by the one or more of the platform 110g of the base 110, the exterior surface 122e of the first upright support 122, and the exterior surface 124e of the second upright support 124.

Support frame 120 also includes various dimensions and/or parameters. As best seen in FIG. 7, support frame 120 defines a height that is measured between the base 110 to the top ends 122a, 124a of the first and second upright supports 122, 124; such height is denoted by a double arrow labeled “H2” in FIG. 7. It should be noted a desired maximum height measured between the bottom end 110f of base 110 and a top end of a building material is approximately 96 inches for transporting; such overall height is denoted by a double arrow labeled “H” in FIG. 8.

Having now discussed the components and elements of pallet assembly 100, a method of using pallet assembly 100 to support and transport building material is discussed in greater detail below. It should be noted, however, that such method of using pallet assembly 100 applies equally to the pallet assembly 1 discussed previously.

As best seen in FIG. 9A, a packer may load and stack a first set of building materials 140a of a building kit 140 onto the base 110 and the support frame 120. Particularly, the first set of building materials 140a is stacked on the first upright support 122 while the base 110 and the first cleat 112a provide additional support to prevent the first set of building material 140a from sliding off or shifting off of the first upright support 122 during transportation. While the first set of building materials 140a is shown being stacked on the first upright support 122, it is contemplated that the first set of building materials 140a may also be stacked on the first upright support 122 and the second upright support 124 depending on the staging operations, which are discussed in greater detail below.

As best seen in FIG. 9B, the packer may then load and/or stack a second set of building materials 140b of the building kit 140 onto the base 110 and the support frame 120. Particularly, the second set of building materials 140b is stacked on the second upright support 124 while the base 110 and the second cleat 112b provide additional support to prevent the second set of building material 140b sliding off or shifting off the second upright support 124 during transportation. While the first set of building materials 140a is shown being stacked on the first upright support 122, it is contemplated that the second set of building materials 140b may also be stacked on the first upright support 122 and the second upright support 124 subsequent to the first set of building materials 140a being stacked on the pallet assembly 100 for staging operations, which are discussed in greater detail below.

While it is illustrated that the second set of building materials 140b is being placed on the pallet assembly 100 after the first set of building materials 140a, it should be understood that the second set of building materials 140b may be loaded on the pallet assembly 100 concurrently with the first set of building materials 140a. Since both the first upright support 122 and the second upright support 124 are easily accessible, two or more packers may stack and load the pallet assembly 100 with the first set of building materials 140a and the second set of building materials 140b to reduce labor and the shipping timeline for the building kit 140.

Packer of pallet assembly 100 may also load and/or stack a third set of building materials 140c of the building kit 140 onto the base 110 and inside of the support frame 120. Particularly, and as best seen in FIG. 9C, the third set of building materials 140c is loaded inside of the storage compartment 130 that is collectively defined by the base 110, the first upright support 122, and the second upright support 124. In this example, the third set of building materials 140c includes one or more windows for building kit 140, hardware and fasteners, and other various items or materials that are capable of being stored inside of the storage compartment 130. By housing such smaller items or materials inside of the storage compartment 130, builders of building kit 140 may quickly access hardware and smaller items of the third set of building materials 140c to reduce the overall construction time of building kit 140 by staging such third set of building materials 140c in the storage compartment 130.

While it is illustrated that the third set of building materials 140c is being placed on the pallet assembly 100 after the first and second sets of building materials 140a, 140b, it should be understood that the third set of building materials 140c may be loaded on the pallet assembly 100 concurrently with the first and second sets of building materials 140a. Since the storage compartment 130 is easily accessible and is free from interfering with packers that are loading materials onto the first and second upright supports 122, 124, a packer may stack and load the pallet assembly 100 with the third set of building materials 140c at the same time to reduce labor and the shipping timeline for the building kit 140.

Such packaging arrangement and capabilities of the pallet assembly 100 may ease steps of constructing the building kit 140. Particularly, the arrangement of the building materials 140a, 140b, 140c on the pallet assembly 100 may be organized in such a way where the first set of building materials 140a is removed from the pallet assembly 100 first to begin the building process of building kit 140 while the second set of building materials 140b is removed from the pallet assembly 100 after the first set of building materials 140a for construction needs. Such staging operations are discussed in greater detail below. Moreover, the arrangement of the building materials 140a, 140b, 140c on the pallet assembly 100 may be organized in such a way where the first and second set of building materials 140a, 140b are staged at an upright position to reduce fatigue and labor on builders that are unloading the first and second set of building materials 140a, 140b from the pallet assembly 100.

Once the building kit 140 is loaded onto the pallet assembly 100 in a predetermined staging configuration, a mover or logistics personal may then load the pallet assembly 100 supporting the building kit 140 onto a vehicle 160 by a pallet jack 150 or similar tool configured to lift and move pallets. As best seen in FIG. 10A, forks 150a of pallet jack 150 engages with the base 110 of the pallet assembly 100 to lift and move the pallet assembly 100 supporting the building kit 140.

Once the pallet assembly 100 is lifted by the pallet jack 150, the mover may then move the pallet assembly 100 and the pallet jack 150 onto a liftgate 160a of the vehicle 160 (FIG. 10B). The size, shape, and configuration of the pallet assembly 100 allows movers to easily place the pallet assembly 100 on the liftgate 160a of the vehicle 160 with the pallet jack 150 that is supporting the pallet assembly 100 and the building kit 140.

At this point, the mover may then raise the liftgate 160a from a ground surface to a cargo or storage area 160b of the vehicle 160 to store the pallet assembly 100. Once the liftgate 160a is even with a floor of the cargo area 160b, the mover may then load and store the pallet assembly 100 loaded with building kit 140 into the cargo area 160b for delivery operations (see FIG. 10C). It should be noted that the overall height of the pallet assembly 100 and the building kit 140 is less than the overall height of the illustrated cargo area 160b to omit additional logistic or shipping costs for said building kit 140. As stated previously, the overall height of the pallet assembly 100 and the building kit 140 is less than 96 inches in height (or less than eight feet in height) to prevent additional logistic or shipping costs for said building kit 140.

Once the pallet assembly 100 and the building kit 140 is loaded into the vehicle 160, the mover may repeat such loading operations described above and as illustrated in FIGS. 10A-10C for additional pallet assemblies loaded with building kits (similar to pallet assembly 100 loaded with the building kit 140).

Once the pallet assembly 100 loaded with the building kit 140 is delivered to a customer, the building kit 140 may be constructed into a preconfigured building 142. As discussed previously, the building kit 140 is staged on the pallet assembly 100 in a predetermined arrangement to reduce the time to construct the building kit 140. As discussed in greater detail below, such staging of the building kit 140 enables builders of the building kit 140 to simply start at a first end or position of the pallet assembly 100 for unloading a set of building materials of the building kit 140 or to start with the outermost building materials of the building kit 140 loaded onto the pallet assembly 100.

In one example, a builder of the building kit 140 may first unload and use the first set of building materials 140a of building kit 140 to construct the building 142 based on installation instructions 170 included with building kit 140 (see FIG. 14). As best seen in FIG. 11, builder may follow a first step 170a of installation instructions 170 to begin at a first end of the pallet assembly 100 when removing building materials from the pallet assembly 100. Particularly, the builder may begin at the first end 110a of the base 110 and/or at the first upright support 122 of support frame 120 when removing building materials from the pallet assembly 100. By beginning at the first end 110a of the base 110 and/or at the first upright support 122 of support frame 120, the builder will remove the first set of building materials 140a from the pallet assembly 100. In this example, the first set of building materials 140a is used to construct a first section or portion 142a of the building 142, which may include the foundation, the framing, and roof of the building 142 in this example.

Continuing with this example, builder of the building kit 140 may then unload and use the second set of building materials 140b of building kit 140 to construct another section or portion of the building 142 based on installation instructions 170 included with building kit 140. As best seen in FIG. 12, builder follows a second step 170b of installation instructions 170 to begin at a second end of the pallet assembly 100 when removing building materials from the pallet assembly. Particularly, the builder may move to the second end 110b of the base 110 and/or at the second upright support 124 of support frame 120 when removing building materials from the pallet assembly 100. By moving to the second end 110b of the base 110 and/or at the second upright support 124 of support frame 120, the builder will remove the second set of building materials 140b from the pallet assembly 100. In this example, the second set of building materials 140b is used to construct a second section or portion 142b of the building 142, which may include the structural walls, siding, and other components of building 142, that are secured to the first set of building materials 140a.

Continuing with this example, builder of the building kit 140 may then unload and use the third set of building materials 140c of building kit 140 to construct a final section or portion of the building 142 based on installation instructions 170 included with building kit 140. As best seen in FIG. 13, builder follows a third step 170c of installation instructions 170 to begin at the storage compartment 130 of the pallet assembly 100 when removing building materials from the pallet assembly. By moving to the storage compartment 130 defined by the base 110 and the support frame 120, the builder will remove the third set of building materials 140c from the pallet assembly 100. In this example, the third set of building materials 140c is used to construct a third section or portion 142c of the building 142, which may include windows, fixtures, and other hardware used on the building 142, that are secured to the first set of building materials 140a and/or second set of building materials 140b.

It should be noted that the third set of building materials 140c may include fasteners and other fastening hardware to construct the building 142 when the first set of building materials 140a and the second set of building materials 140b are used. With such inclusion of the fasteners and other fastening hardware in the third set of building materials 140c, builders may quickly access such fasteners and other fastening hardware in a centralized area or zone.

It should be understood that such staging of building kit 140 may be arranged in any suitable configuration based on the various considerations, including the size or shape of building materials, the various types of building materials, and other considerations of the like. In one exemplary embodiment, a first set of building materials may be supported by a first upright support and a second upright support of a support frame mentioned herein instead of said first set of building materials being supported by a single upright support. In this same embodiment, a second set of building materials may be supported by the same first upright support and second upright support of the support frame instead of said second set of building materials being supported by a single upright support. In this embodiment, the second set of building materials would be laying or resting on the first set of building materials such that the second set of building materials are positioned at a distance away from the same first upright support and second upright support. With such arrangement, the builder would initially remove the second set of building material from the pallet assembly to build a first section or portion of the building and then remove the first set of building material from the pallet assembly to build a second section or portion of the building. This staging of a building kit on a pallet assembly may be desired when the sets of building material have differing lengths, weights, or configurations to prevent unwanted tipping or imbalances on the pallet assembly when stationary or when transported.

It should be understood that building materials of any set of building kits discussed and illustrated herein (e.g., building kits 40, 140) may be pre-cut or pre-fabricated for constructing a given building. In one instance, a first set of pre-cut materials (e.g., building materials 140a) may be pre-cut or pre-fabricated at a predetermined first length or set of first dimensions that are loaded onto an upright support of a support frame discussed and illustrated herein. In this same instance, a second set of pre-cut materials (e.g., building materials 140b) may be pre-cut or pre-fabricated at a predetermined second length or set of second dimensions that are loaded onto an upright support of a support frame discussed and illustrated herein. In this instance, the set of first dimensions of the first set of pre-cut materials and the set of second dimensions of the second set of pre-cut materials are different from one another for constructing a given building.

FIG. 15 illustrates a method 200 of packaging a building kit to a pallet assembly. An initial step 202 of method 200 includes engaging a base of the pallet assembly with an A-frame of the pallet assembly. Another step 204 of method 200 includes loading a first set of building materials of the building kit the A-frame and onto the base. Another step 206 of method 200 includes loading a second set of building materials of the building kit onto the A-frame and onto the base of the pallet assembly, wherein the first set of building material is positioned between the A-frame and the second set of building material.

In other exemplary embodiments, method 200 may include additional or optional steps of packaging a building kit to a pallet assembly. In one exemplary embodiment, method 200 may further include steps of supporting the first set of building material, by a first upright support of the A-frame, at a first angle measured between the first upright support and the base; and supporting the second set of building material, by a second upright support of the A-frame, at a second angle measured between the first upright support and the base; wherein the second angle is greater than the first angle. In another exemplary embodiment, method 200 may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. In another exemplary embodiment, method 200 may further include that the second angle measured between the second upright support and the base is approximately 85 degrees. In another exemplary embodiment, method 200 may further include steps of defining a first length of the first upright support measured between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and defining a second length of the second upright support measured between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. In another exemplary embodiment, method 200 may further include a step of supporting the first set of building material, by the first upright support, that defines a length that is greater than the first length of the first upright support. In another exemplary embodiment, method 200 may further include a step of supporting the second set of building material, by the second upright support, that defines a length that is less than the first length of the first upright support. In another exemplary embodiment, method 200 may further include that the step of engaging the base with the A-frame further comprises: engaging a top end of the base with the first end of the first upright support and the first end of the second upright support; interfacing a bottom end of the base with a ground surface, wherein the bottom end is opposite to the top end; and defining an overall height between the first end of the second upright support and the bottom end; wherein the overall height is less than the first length of the first upright support. In another exemplary embodiment, method 200 may further include that the overall height is less than 96 inches. In another exemplary embodiment, method 200 may further include that the step of engaging the base with the A-frame further comprises: engaging the first end of the first upright support with the base; and positioning the second end of the first upright support above the first end of the first upright support such that the second end of the first upright support is free from engaging with the first end of the second upright support. In another exemplary embodiment, method 200 may further include that the step of engaging the base with the A-frame further comprises: engaging the first end of the second upright support with the base; and engaging the second end of the second upright support with the first upright support at a location between the first end of the first upright support and the second end of the first upright support. In another exemplary embodiment, method 200 may further include a step of loading a third set of building materials inside of a storage compartment of the pallet assembly; wherein the storage compartment is collectively defined by the base, a first upright support of the A-frame, and the second upright support of the A-frame. In another exemplary embodiment, method 200 may further include a step of engaging a pair of cleats with the base and being spaced apart from the A-frame. In another exemplary embodiment, method 200 may further include steps of positioning a first cleat of the pair of cleats at a first distance measured from a first upright support of the A-frame; and positioning a second cleat of the pair of cleats at a second distance measured from a second upright support of the A-frame; wherein the first distance is greater than the second distance. In another exemplary embodiment, method 200 may further include steps of supporting the first set of building material on the first cleat and the first upright support; and supporting the second set of building material on the second cleat and the second upright support. In another exemplary embodiment, method 200 may further include steps of engaging a first pair of cross members of a first upright support of the A-frame with a first pair of lateral upright supports; and engaging a second pair of cross members of a second upright support of the A-frame with a second pair of lateral upright supports. In another exemplary embodiment, method 200 may further include steps of aligning a first cross member of the first pair of cross members and a first cross member of the second pair of cross members with one another; and positioning a second cross member of the first pair of cross members is positioned below a second cross member of the second pair of cross members. In another exemplary embodiment, method 200 may further include a step of securing a first pair of lateral supports with a first upright support of the A-frame and a second upright support of the A-frame and being spaced apart from the base. In another exemplary embodiment, method 200 may further include a step of securing a second pair of lateral supports with the first upright support and the second upright support and being secured to the base.

FIG. 16 illustrates a method 300 of staging a building kit on a pallet assembly. An initial step 302 of method 300 includes engaging a base of the pallet assembly with a support frame of the pallet assembly, the support frame comprising: a first upright support of the support frame operably engaged with the base at a first position; and a second upright support of the support frame operably engaged with the base at a second position opposite to the first position; wherein the support frame has an A-shaped configuration. Another step 304 of method 300 includes staging a building kit onto the pallet assembly in a preconfigured arrangement. Another step 306 of method 300 includes effecting the building kit to be removed in a predetermined order of operations. Another step 308 of method 300 includes effecting a building to be constructed from the building kit based on the preconfigured arrangement.

In other exemplary embodiments, method 300 may include additional or optional steps of staging a building kit on a pallet assembly. In one exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: supporting the building kit, by the support frame, along at least one plane of the support frame that is non-parallel to the base. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: supporting a first set of building materials of the building kit, by the first upright support, along a first plane relative to the base; and supporting a second set of building materials of the building kit, by the second upright support, along a second plane relative to the base; wherein the first plane and the second plane are each non-parallel to the base. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a first set of building materials of the building kit onto the base and the support frame at a first position; and staging a second set of building materials of the building kit onto the base and the support frame at a second position opposite to the first position; wherein the first set of building materials and the second set of building materials are separated from one another by the support frame. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a third set of building materials inside of a storage compartment defined by the support frame and the base, collectively; wherein the third set of building materials is separated from the first set of building materials and the second set of building materials by the support frame. In another exemplary embodiment, method 300 may further include that the step of effecting the building kit to be removed further comprises: effecting the first set of building materials to be removed from the support frame and the base at the first position in a first step of the predetermined order of operations; wherein the first set of building materials is adapted to build a first portion of the building kit. In another exemplary embodiment, method 300 may further include that the step of effecting the building kit to be removed further comprises: effecting the second set of building materials to be removed from the support frame and the base at the second position in a second step of the predetermined order of operations subsequent to the first step; wherein the second set of building materials is adapted to build a second portion of the building kit. In another exemplary embodiment, method 300 may further include the step of effecting the building kit to be removed further comprises: effecting a third set of building materials of the building kit to be removed from the support frame and the base at a third position in a third step of the predetermined order of operations subsequent to the first step and the second step; wherein the third set of building materials is adapted to build a third portion of the building kit. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a first set of building materials of the building kit onto the base and the support frame; and staging a second set of building materials of the building kit onto the base and the support frame; wherein the second set of building materials is supported by the first set of building materials on the support frame. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises: staging a third set of building materials inside of a storage compartment defined by the support frame and the base, collectively; wherein the third set of building materials is separated from the first set of building materials and the second set of building materials by the support frame. In another exemplary embodiment, method 300 may further include that the step of effecting the building kit to be removed further comprises effecting the second set of building materials to be removed from the support frame and the base in a first step of the predetermined order of operations; and wherein the first set of building materials is adapted to build a first portion of the building kit. In another exemplary embodiment, method 300 may further include that the step of effecting the building kit to be removed further comprises: effecting the first set of building materials to be removed from the support frame and the base in a second step of the predetermined order of operations subsequent to the first step; wherein the second set of building materials is adapted to build a second portion of the building kit. In another exemplary embodiment, method 300 may further include that the step of effecting the building kit to be removed further comprises: effecting a third set of building materials of the building kit to be removed from the support frame and the base in a third step of the predetermined order of operations subsequent to the first step and the second step; wherein the third set of building materials is adapted to build a third portion of the building kit. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprising: supporting the building kit with a pair of cleats on the base, wherein the pair of cleats is spaced apart from the first upright support and the second upright support. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprising: supporting a first set of building materials of the building kit with a first cleat on the base, wherein the first cleat is spaced apart from the first upright support; and supporting a second set of building materials of the building kit with a second cleat on the base, wherein the second cleat is spaced apart from the second upright support. In another exemplary embodiment, method 300 may further include that the step of staging the building kit onto the pallet assembly further comprises that a total height measured between the pallet assembly and the building kit is less than or equal to eight feet. In another exemplary embodiment, method 300 may further include steps of supporting a first set of building materials of the building kit, by the first upright support, at a first angle measured between the first upright support and the base; and supporting a second set of building materials of the building kit, by the second upright support, at a second angle measured between the first upright support and the base; and wherein the second angle is greater than the first angle. In another exemplary embodiment, method 300 may further include that the first angle measured between the first upright support and the base is approximately 70 degrees. In another exemplary embodiment, method 300 may further include that the second angle measured between the second upright support and the base is approximately 85 degrees.

FIG. 17 illustrates a method 400 of packaging at least one set of pre-cut materials on a pallet assembly. An initial step 402 of method 400 includes engaging a base of the pallet assembly with an A-frame of the pallet assembly. Another step 404 of method 400 includes loading a first set of pre-cut materials of the building kit the A-frame and onto the base. Another step 406 of method 400 includes loading a second set of pre-cut materials of the building kit onto the A-frame and onto the base of the pallet assembly. Another step 408 of method 400 includes supporting the first set of pre-cut materials at a first upright position by the A-frame. Another step 410 of method 400 includes supporting the second set of pre-cut materials at a second upright position by the A-frame.

In other exemplary embodiments, method 400 may include additional or optional steps of packaging at least one set of pre-cut materials on a pallet assembly. In one exemplary embodiment, method 400 may further include that the steps of supporting the first set of pre-cut materials and the second set of pre-cut materials further comprises: supporting the first set of pre-cut materials, by a first upright support of the A-frame, at a first angle measured between the first upright support and the base; and supporting the second set of pre-cut materials, by a second upright support of the A-frame, at a second angle measured between the first upright support and the base; wherein the second angle is greater than the first angle. In another exemplary embodiment, method 400 may further include that the first angle measured between the first upright support and the base is approximately 70 degrees; and wherein the second angle measured between the second upright support and the base is approximately 85 degrees. In another exemplary embodiment, method 400 may further include steps of defining a first length of a first upright support of the A-frame measured between a first end of the first upright support and a second end of the first upright support that is opposite to the first end of the first upright support; and defining a second length of a second upright support of the A-frame measured between a first end of the second upright support and a second end of the second upright support that is opposite to the first end of the second upright support; wherein the first length is greater than the second length. In another exemplary embodiment, method 400 may further include a step of supporting the first set of pre-cut materials, by the first upright support, that defines a length that is greater than or equal to the first length of the first upright support. In another exemplary embodiment, method 400 may further include a step of supporting the second set of pre-cut materials, by the second upright support, that defines a length that is less than or equal to the second length of the second upright support.

It should be understood that the use of term “upright” and derivatives of the term “upright” with components or parts of pallet assemblies mentioned herein, including pallet assemblies 1, 100, simply means that a component or part of a given pallet assembly is orientated at an angle or position that is non-parallel to another component of said pallet assembly. In one example, an upright support mentioned herein, such as upright supports 22, 24, 122, 124, is orientated at an angle or position that is non-parallel to a base, such as bases 10, 110, of said pallet assembly. As such, components or parts of a pallet assembly mentioned herein using the term “upright” may be oriented at a position that is non-parallel to, orthogonal to, or perpendicular to another component of said pallet assembly.

The articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and/or,” as used herein in the specification and in the claims (if at all), should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. As another example, “at least one of: A, B, or B” is intended to cover A, B, C, A-B, A-C, B-C, and A-B-C, as well as any combination with multiple of the same item.

While components of the present disclosure are described herein in relation to each other, it is possible for one of the components disclosed herein to include inventive subject matter, if claimed alone or used alone. In keeping with the above example, if the disclosed embodiments teach the features of A and B, then there may be inventive subject matter in the combination of A and B, A alone, or B alone, unless otherwise stated herein.

As used herein in the specification and in the claims, the term “effecting” or a phrase or claim element beginning with the term “effecting” should be understood to mean to cause something to happen or to bring something about. For example, effecting an event to occur may be caused by actions of a first party even though a second party actually performed the event or had the event occur to the second party. Stated otherwise, effecting refers to one party giving another party the tools, objects, or resources to cause an event to occur. Thus, in this example a claim element of “effecting an event to occur” would mean that a first party is giving a second party the tools or resources needed for the second party to perform the event, however the affirmative single action is the responsibility of the first party to provide the tools or resources to cause said event to occur.

When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “above”, “behind”, “in front of”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”, “lateral”, “transverse”, “longitudinal”, and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

Although the terms “first” and “second” may be used herein to describe various features/elements, these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed herein could be termed a second feature/element, and similarly, a second feature/element discussed herein could be termed a first feature/element without departing from the teachings of the present disclosure.

An embodiment is an implementation or example of the present disclosure. Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” “an exemplary embodiment,” or “other embodiments,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” “an exemplary embodiment,” or “other embodiments,” or the like, are not necessarily all referring to the same embodiments. Furthermore, the use of any and all examples or exemplary language (“e.g.,” “such as,” or the like) is intended merely to better illustrate or illuminate the embodiments and does not pose a limitation on the scope of that or those embodiments. No language in this specification should be construed as indicating any unclaimed element as essential to the practice of the disclosed embodiment.

If this specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element or “another” element, that does not preclude there being more than one of the additional element or the another element.

As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/−0.1% of the stated value (or range of values), +/−1% of the stated value (or range of values), +/−2% of the stated value (or range of values), +/−5% of the stated value (or range of values), +/−10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein. Further, recitation of ranges of values herein are not intended to be limiting, referring instead individually to any and all values falling within that range, unless otherwise indicated herein, and each separate value within such range is incorporated into the specification as if it were individually recited herein.

Additionally, the method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

To the extent that the present disclosure has utilized the term “invention” in various titles or sections of this specification, or in the context of those sections, this term has been included as required by the formatting requirements of word document submissions (i.e., docx submissions) pursuant the guidelines/requirements of the United States Patent and Trademark Office and shall not, in any manner, be considered a disavowal of any subject matter.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described.