Plastic pallet design

Abstract

A pallet, comprising: an upper deck; a lower frame member arranged in a parallel planar relationship with the upper deck; a plurality of foot members connected to the upper deck and the lower frame member; and a reinforcement member positioned in physical contact with the upper deck. The reinforcement member comprises: a first plate, a second plate disposed in a spaced relationship with the first plate, and a support element disposed between the first plate and the second plate. The support element further comprises a support member disposed between and normal to facing surfaces of the first plate and the second plate, wherein a support material is disposed adjacent to the support member, and wherein the support material comprises foam.

What is claimed is:  
     
         1 . A pallet, comprising: 
 an upper deck;    a lower frame member arranged in a parallel planar relationship with said upper deck;    a plurality of foot members connected to said upper deck and said lower France member; and    a reinforcement member positioned in physical contact with said upper deck, said reinforcement member comprising, 
 a first plate,  
 a second plate disposed in a spaced relationship with said first plate, wherein said first plate and said second plate each include at least one appendage depending therefrom, and  
 a support element disposed between said first plate and said second plate, wherein said support element further comprises a support member disposed between and normal to facing surfaces of said first plate and said second plate, wherein a support material is disposed adjacent to said support member, and wherein said support material comprises foam.  
   
     
     
         2 . The pallet of  claim 1 , wherein said appendages comprise a knobbed portion on an end distal from an end at which said appendages are connected to either said first plate or said second plate.  
     
     
         3 . The pallet of  claim 1 , wherein said appendages comprise tabs cut out of said first plate or said second plate, said tabs being configured to protrude into said rigid support material.  
     
     
         4 . The pallet of  claim 1 , further comprising a second reinforcement member positioned in physical contact with said lower frame member.  
     
     
         5 . The pallet of  claim 1 , wherein the pallet has a weight of less than or equal to about 4.5 lb/ft 2 .  
     
     
         6 . The pallet of  claim 5 , wherein the weight is about 2.5 lb/ft 2  to about 4.5 lb/ft 2 .  
     
     
         7 . A pallet, comprising: 
 an upper deck;    a lower frame member arranged in a parallel planar relationship with said upper deck;    a plurality of foot members connected to said upper deck and said lower frame member; and    a first reinforcement member positioned in physical contact with said upper deck and a second reinforcement member positioned adjacent the lower frame member and in a spaced relation to said first reinforcement member, said first reinforcement member and said second reinforcement each comprising, 
 a first plate,  
 a second plate disposed in a spaced relationship with said first plate, and  
 a support element disposed between said first plate and said second plate;  
   wherein the pallet has a weight of less than or equal to about 4.5 lb/ft 2 .    
     
     
         8 . The pallet of  claim 7 , wherein the weight is about 2.5 lb/ft 2  to about 4.5 lb/ft 2 .  
     
     
         9 . The pallet of  claim 7 , wherein said support element comprises foam.  
     
     
         10 . A plastic pallet, comprising: 
 a plastic upper deck;    a plastic lower frame member arranged in a parallel planar relationship with said upper deck;    a plurality of plastic foot members connected to said upper deck and said lower frame member; and    a first reinforcement member positioned in physical contact with said upper deck and a second reinforcement member positioned adjacent the lower frame member and in a spaced relation to said first reinforcement member, said first reinforcement member and said second reinforcement each comprising, 
 a first metal plate,  
 a second metal plate disposed in a spaced relationship with said first plate, and  
 a support element disposed between said first metal plate and said second metal plate;  
   wherein the pallet has a weight of less than or equal to about 4.5 lb/ft 2 .    
     
     
         11 . The pallet of  claim 10 , wherein said support element comprises foam.  
     
     
         12 . The pallet of  claim 10 , wherein said support element further comprises a side support.  
     
     
         13 . A reinforcement structure disposed within a deck of a pallet, said reinforcement structure comprising: 
 a first reinforcement member extending in a non-parallel direction to a first edge of said deck;    a second reinforcement member extending from a point on said first reinforcement member intermediate ends of said first reinforcement member toward a second edge of said deck adjacent to said first edge; and    a third reinforcement member extending from a point on said first reinforcement member intermediate the ends of said first reinforcement member toward a third side of said deck opposite said second side.    
     
     
         14 . The reinforcement structure of  claim 13 , wherein said second reinforcement member and said third reinforcement member are attached to opposing sides of said first reinforcement member.  
     
     
         15 . A reinforcement structure disposed within a deck of a pallet, said reinforcement structure comprising: 
 a first reinforcement member extending toward a first edge of said deck; and    a second reinforcement member crossing over said first reinforcement member and extending toward a second edge of the deck, wherein the second edge is disposed adjacent the first edge.    
     
     
         16 . The reinforcement structure of  claim 15 , wherein a point at which said first reinforcement member crosses over said second reinforcement member occurs at a point intermediate opposing ends of said first reinforcement member and intermediate opposing ends of said second reinforcement member.  
     
     
         17 . The reinforcement structure of  claim 16 , wherein the point at which said first reinforcement member crosses over said second reinforcement member results in a point having an increased thickness, the point of increased thickness being positioned to be concealable within a foot member disposed adjacent said deck.  
     
     
         18 . A reinforcement structure disposed within a deck of a pallet, the reinforcement structure comprising: 
 a structural hub member, said structural hub member being disposable substantially equidistant from edges of the deck; and    a plurality of reinforcement members supported at said structural hub member and extendable toward the edges of the deck, wherein at least two reinforcement members of the plurality of said reinforcement members have an end received at said structural hub member.    
     
     
         19 . A reinforcement structure disposed within a deck of a pallet, the reinforcement structure comprising: 
 a first reinforcement member having an opening disposed laterally therethrough; and    a second reinforcement member received through said opening defined by said first reinforcement member, said second reinforcement member being extendable between opposing edges of the deck.