Method of reinforcing a plastic pallet

A method of reinforcing a loadable plastic pallet having a top deck portion, a plurality of support columns extending from the top deck portion and a plurality of relatively weak support rails which tend to deflect when the pallet is loaded extending between the support columns, wherein the support rails include a sheet portion with a plurality of vertical ribs extending therefrom, and wherein the sheet portion and ribs cooperate to form a plurality of U-shaped vertical cross-sections along the length of the pallet and each U-shaped cross-section having an open end, the method comprising:

• welding a plurality of planar plastic sheets to the vertical ribs of the support rails to close the respective open ends of said U-shaped cross-sections to form a sufficient number of substantially rectangular hollow vertical boxed cross-sections along the length of the support rails so that the support rails become sufficiently stiff such that they do not deflect when the pallet is loaded.

A method of reinforcing a plastic pallet having a thin top deck connected to a thin bottom deck by nine support columns, wherein the thin bottom deck comprises a plurality of relatively weak support rails each having a U-shaped vertical cross-section which tends to deflect when the pallet is loaded extending between the support columns, the method comprising:

• welding a plastic reinforcement member to each of the relatively weak support rails, such that each reinforcement member and the respective support rail cooperate to form a sufficient number of substantially rectangular vertical cross-sections along the length of the support rail so that the support rails become sufficiently stiff that they do not deflect when the pallet is loaded,
• wherein each said support rail comprises a sheet portion, and each said plastic reinforcement member comprises an extruded rectangular tube which is welded to the respective sheet portion to form said substantially rectangular vertical cross-sections.

A method of making a plastic pallet of improved stiffness comprising:

• injection molding a deck portion consisting of a plurality of vertical ribs at least some of which extend sufficently from the deck portion to form spaced pockets adapted to receive respective support columns and at least others of which extend sufficiently from the deck portion to form a plurality of reduced weight, open-sided hollows extending between the pockets and defining relatively weak support rails which deflect when the pallet is loaded;
• and
• affixing a plurality of separate planar strips respectively over the open sides of the open-sided hollows to close the open side sufficiently to form a sufficient number of substantially rectangular hollow cross-sections along the respective weak support rails so that the support rails become sufficiently stiff such that they do not deflect when the pallet is loaded.

A plastic pallet comprising:

• at least one deck member having a substantially planar deck portion with a plurality of columns portions projecting substantially from the deck portion and a plurality of support rails defining the deck portion and extending between the columns portions, each support rail including a plurality of vertical ribs extending therefrom to form a plurality of open boxed sections;
• and
• a plurality of planar sheet members, each affixed to a corresponding support rail between the column portions to define a plurality of closed box sections along the length of the support rails for providing sufficient stiffness to the support rails to enhance resistance to deflection when the pallet is loaded.