Thermoplastic pallet

Abstract

An improved load bearing pallet formed of a thermoplastic material is provided. The pallet includes at least an upper deck formed from a sheet of thermoplastic material with a load engaging surface on one side of the sheet, and a lift engaging surface on the other. A number of features such as ridges, channels, depressions, and legs, are formed in the sheet with corresponding features being necessarily defined by the sheet on the opposite side. In particular, the pallet preferably includes a peripheral channel formed around a periphery of the upper deck and nine legs positioned in three rows of three creating two gaps on each side of the pallet for the tines of a fork lift to enter to lift the pallet. The pallet also preferably includes a plurality of strengthening ridges and channels on the load bearing surface of the upper deck, with corresponding channels and ridges necessarily formed in the lifting surface of the upper deck, to resist bending and folding of the pallet. The pallet may further include at least one reinforcing member received within the peripheral channel. The reinforcing member preferably includes a steel core encapsulated within a thermoplastic coating that is molecularly bonded or cross-linked to the molecular structure of the thermoplastic material of the pallet. The pallet may additionally include a lower deck or other support structure, preferably molecularly bonded to the upper deck. The lower deck may also include ridges, channels, depressions, legs, and reinforcing members as desired.