Low profile plastic pallet

A GMA type pallet for use with a fork lift device which comprises:

• a rectangular base comprised of outer rails arranged in a rectangular pattern and cross rails connecting the opposing side midpoints of the outer rails, the rails having steel reinforcing beams;
• eight spaced apart outer columns extending upwardly from the outer rails and one center column extending upwardly from the center of the base;
• a 40 inch by 48 inch top, attached to the outer columns;
• the top comprised of a thermoplastic rectangular frame, a subframe and a corrugated sheet metal deck;
• wherein, the deck made of aluminum alloy sheet and has a circumscribing flange and at least three continuous corrugations running from one corner of the deck to a diagonally opposed corner of the deck;
• wherein, the frame forms the periphery of the top and comprises bridges which span the spaces between the columns;
• wherein each bridge comprises a multiplicity of vertical ribs which bound closed cells within the bridge;
• wherein the deck flange is attached to the subframe;
• wherein the edges of the deck are spaced apart at least 4 inches from the exterior edges of the frame;
• wherein the pallet is predominately comprised of a molded polyolefin selected from polyurethane and polypropylene and combinations thereof;
• wherein the metal parts weigh less than 40 percent of the weight of the whole pallet;
• and
• wherein the pallet has
• (a) two forklift device openings on each side of the pallet, bounded by the bridges and the outer rails and adjacent outer columns, each opening having a height of at least about 3.1 inches (79 mm) and a width of 12 inches (305 mm);
• (b) a height less not exceeding 5.5 inches (141 mm);
• and
• (c) a stacked pallet density property which is greater than 2.2 pallets per vertical foot (7.2 pallets per meter).

The method of making a GMA type thermoplastic pallet, wherein the pallet has a top mounted on columns extending upwardly from the base, wherein the pallet has properties which include (a) a racking creep strength such that, when the pallet deck is subjected to a uniform load of 2800 pounds (1270 kg) for a period of 720 hours at a temperature of 115° F. (46° C.), while the pallet is supported along opposing 48 inch (1220 mm) sides by rack beams which are spaced apart 45 inches (1145 mm), the center of the pallet deflects 0.8 inches (2 mm) or less;

• and (b) a fire test performance which meets Underwriters Laboratories fire test standard UL 2335, which comprises:
• providing the pallet base with steel reinforcing beams;
• providing the pallet with a top comprised of a plastic frame and a corrugated sheet metal deck which is inset from the outer edges of the frame and which has an area which is at least 75 percent of the area of the top of the pallet;
• wherein the corrugations of the deck comprise at least three of the corrugations which run diagonally from comer to comer of the deck;
• to thereby reduce the thermoplastic content of the deck to less than 70 percent of the weight of the pallet.