Plastic pallet with sealed deck to frame joint

Abstract

A deck, e.g., a metal deck, is bonded to the molded plastic frame of a pallet in sealing engagement, e.g., by one or more means including a coating on the deck, which is melted to adhere the deck to the frame, an adhesive provided within a recess of the frame, and injection molding aspects configured to bond the deck to the frame.

1 . A pallet, comprising: 
 a molded plastic frame; and    a deck, wherein the deck is bonded to the molded plastic frame in sealing engagement an at least partially melted coating, an adhesive provided within a recess of the frame, or an injection molded frame portion, which portion engages a peripheral portion of said deck.    
   
   
       2 . A pallet in accordance with  claim 1 , wherein said deck is bonded to the molded plastic frame with an injection molded frame portion, wherein the injected molded frame portion is disposed at least partially within a cavity of the deck.  
   
   
       3 . A pallet in accordance with  claim 2 , wherein said injection molded frame portion forms a nub, which is provided as injection molded in a shaped hole on the deck.  
   
   
       4 . A pallet in accordance with  claim 2 , wherein said injection molded frame portion forms a lip, which is provided at least partially over an upper peripheral edge of said deck.  
   
   
       5 . A pallet in accordance with  claim 1 , wherein the deck is bonded to the frame by a partially melted coating.  
   
   
       6 . A pallet in accordance with  claim 5 , wherien the coating is polypropylene, polyethylene, thermoplastic olefin, or one of known powder coatings for metals.  
   
   
       7 . A pallet in accordance with  claim 5 , wherein the coating completely covers the deck surfaces.  
   
   
       8 . A pallet in accordance with  claim 1 , wherein the deck is bonded to the frame by an adhesive.  
   
   
       9 . A pallet in accordance with  claim 8 , wherein the adhesive comprises an L-Shaped strip provided along an L-Shaped contour between the frame and the deck.  
   
   
       10 . A method of making a pallet having a molded plastic frame and a deck, comprising: bonding the deck to the molded plastic frame in sealing engagement an at least partially melted coating, an adhesive provided within a recess of the frame, or an injection molded frame portion, which portion engages a peripheral portion of said deck.  
   
   
       11 . A method of making a pallet having a molded plastic frame and a deck, comprising: forming a recess in the frame to receive the deck, placing an adhesive in the strip, and placing the deck into the recess to attach the deck to the frame.  
   
   
       12 . A method of making a pallet having a molded plastic frame and a deck, comprising: providing a multiplicity of perforations in the deck, placing the deck in an injection machine mold, and injecting plastic into the mold to form the frame, and to cause plastic to flow through the holes, to thereby form nubs which are integral to the frame and which hold the deck onto the frame.  
   
   
       13 . A method of making a pallet having a molded plastic frame and a deck, comprising: placing the deck in an injection machine mold, and injecting plastic into the mold to form the frame, so that a lip is formed over a top surface of the deck, as it rests on and within the frame during use of the pallet.