Plastic pallet having metal deck

Abstract

A molded plastic pallet has a base comprised of steel beam-reinforced thermoplastic rails reinforced with steel beams, vertical columns, a frame on top of the columns, and a textured metal deck. The metal deck preferably comprises a flange which is attached to the frame or to a subframe which is within the opening of the frame. The edge of the deck is inset from the outer edge of the frame, and the periphery of the top of the frame is exposed. The frame preferably has one or more impact absorbing zones at the bridge portions of the frame, which span the fork openings between adjacent columns.

1 . A predominately plastic pallet comprising: 
 a rectangular base;    a multiplicity of spaced apart outer columns extending upwardly from the periphery of the base;    a top, comprising a rectangular plastic frame having inner edges and outer edges, mounted on the columns, the frame comprising bridges which span the spaces between the columns; deck support means, for attaching the deck to the top;    a textured sheet metal deck, for receiving goods placed on the pallet.    
     
     
         2 . The pallet of  claim 1 , wherein the deck support means comprises attachment of the deck to the frame.  
     
     
         3 . The pallet of  claim 1 , wherein the top further comprises a subframe mounted within the frame with the outer edges of the subframe spaced apart from the inner edges of the frame; wherein the deck support means comprises attachment of the deck to the subframe.  
     
     
         4 . The pallet of  claim 1  wherein the base comprises rails having metal reinforcing beams:  
     
     
         5 . The pallet of  claim 1  wherein the deck is made from a metal selected from the group which comprises: iron base alloys, aluminum base alloys, titanium base alloys, and magnesium base alloys.  
     
     
         6 . The pallet of  claim 4  wherein the deck is made of aluminum alloy and the reinforcing beams are made of iron alloy.  
     
     
         7 . The pallet of  claim 1  wherein the edges of the deck are inset from the outer edges of the frame.  
     
     
         8 . The pallet of  claim 1  wherein the edges of the deck are inset from the outer edges of the frame; and wherein the deck area is at least 75 percent of the area of the top of the pallet.  
     
     
         9 . The pallet of  claim 8  wherein the total weight of the deck and reinforcing beams is between 30 and 45 percent of the total pallet weight.  
     
     
         10 . The pallet of  claim 8  wherein the deck has a circumscribing flange.  
     
     
         11 . The pallet of  claim 7  wherein a multiplicity of the bridges each comprising at least one impact absorber zones running lengthwise along the portion of the bridge which is nearer to the edge than is the adjacent edge of the deck.  
     
     
         12 . The pallet of  claim 1  wherein the deck is attached to the top by a means selected from the group which comprises pins, stakes, screws, headed plastic nubs, and hold-down rails.  
     
     
         13 . The pallet of  claim 1  wherein the deck texturing comprises a multiplicity of parallel continuous corrugations running between opposing diagonal corners of the deck.  
     
     
         14 . The pallet of  claim 1  wherein the base is comprised of four outer rails which form the sides of the rectangle and cross rails which connect the centers of the opposing side outer rails, further comprising: a center column at the intersection of the cross rails; wherein the deck is attached to the center column.  
     
     
         15 . A predominately thermoplastic rectangular pallet comprising: 
 a base comprised of four outer rails interconnected to form a rectangle; at least one cross rail connecting the center points of opposing side outer rails;    reinforcing beams within said rails, the beams having a higher modulus of elasticity than the modulus of elasticity of the thermoplastic material of the pallet;    eight spaced apart outer columns extending upwardly from the outer rails and one center column extending upwardly from the center of the base;    a thermoplastic frame, attached to the tops of the outer columns, the frame having inner edges and outer edges and comprised of a multiplicity of bridges which span the spaces between the columns, each bridge comprising at least one impact absorber zone running lengthwise in proximity to the outer edge of the frame;    a subframe, spaced apart from the inside edge of the frame; means for supporting the subframe;    a textured metal deck attached to the subframe and to the center column, wherein the edges of the deck are inset from the inner edges of the frame; wherein, the combination of frame and deck forming the top of the pallet, for receiving goods placed on the pallet.    
     
     
         16 . The pallet of  claim 15  which is of the GMA type; wherein the frame is 48 inches long and 40 inches wide; wherein the deck is inset about at least 3 inches; where the reinforcing beams are made of steel; and, wherein the pallet is between 30 and 45 weight percent metal.  
     
     
         17 . The pallet of  claim 16  deck is textured with a multiplicity of parallel continuous corrugations running between opposing diagonal corners of the deck.  
     
     
         18 . The pallet of  claim 16  wherein the thermoplastic is selected from the group which comprises polyethylene, polypropylene and combinations thereof.