Pallet assembly

A pallet assembly comprising:

• a first pallet portion formed of plastic and including a top member and a top intermediate member, each having a one of a first pair of substantially planar surfaces spaced apart from the other and each further having a one of a first pair of mating surfaces opposite its respective planar surface which are heat welded together to integrally define a plurality of box-beam sections within the first pallet portion;
• and
• a second pallet portion formed of plastic and including a bottom member and a bottom intermediate member, each having a one of a second pair of substantially planar surfaces spaced apart from the other and each further having a one of a second pair of mating surfaces opposite its respective planar surface which are heat welded together to integrally define a plurality of box-beam sections within the second pallet portion,
• wherein the first intermediate member of the first pallet portion and the second intermediate member of the second pallet portion have corresponding planar, opposed mating cross-ribbed surfaces which are welded to each other for attaching the first and second pallet portions.

A pallet assembly formed substantially of plastic comprising:

• a first outer member and a first intermediate member spaced apart from each other by a first pair of opposed mating multi-directional ribbed surfaces extending therebetween which are integrally mounted to each other to define a first pallet portion having a plurality of box beam sections;
• and
• a second outer member and a second intermediate member spaced apart from each other by a second pair of opposed mating multi-directional ribbed surfaces extending therebetween which are integrally mounted to each other to define a second pallet portion having a plurality of box beam sections, the second intermediate member being oriented adjacent the first intermediate member,
• wherein the first intermediate member and the second intermediate member have corresponding mounting edges projecting therefrom which are attached to each other to define the pallet assembly.

A pallet assembly for storing and transporting objects thereon, comprising:

• a first member having a first upper surface upon which the objects are placed, and a first lower surface defined by a plurality of downstanding cross-rib members;
• a second member having a second lower surface and a second upper surface defined by a plurality of upstanding cross-rib members corresponding to the downstanding cross-rib members of the first member and securely mounted therewith to define a plurality of box beam sections;
• a third member having a third upper surface and a third lower surface defined by a plurality of downstanding cross-rib members, the third upper surface and the second lower surface having corresponding flanged surfaces securely mounted to each other to form a plurality of columns;
• and
• a fourth member having a fourth upper surface defined by a plurality of upstanding cross-rib members corresponding to the downstanding cross-rib members of the third member and securely mounted therewith to define a plurality of box beam sections.

A method of forming a pallet comprising:

• providing first and second pallet portions, each having a pair of surfaces with a plurality of box sections formed therebetween, the first and second pallet portions having corresponding mating cross-ribbed surfaces;
• introducing heat to the corresponding mating cross-ribbed surfaces to melt the mating cross-ribbed surfaces thereby forming plasticized surfaces;
• pressing the plasticized surfaces together;
• and
• cooling the plasticized surfaces forming a welded joint therebetween defining a plurality of column members extending between the first and second pallet portions, each column member having a plurality of box sections formed therein.

A method of forming a plastic pallet assembly, comprising:

• providing a top deck portion having a plurality of top deck box beam sections disposed therein and having a first opposing surface with a plurality of first column portions projecting downwardly therefrom defined by first partial box beam sections having cross-ribbed surfaces;
• providing a bottom deck portion having a plurality of bottom deck box beam sections disposed therein and having a second opposing surface with a plurality of second column portions projecting upwardly therefrom defined by second partial box beam sections having cross-ribbed surface;
• and
• securely attaching the plurality of second column portions to corresponding plurality of first column portions to define a plurality of box beam cross-sections between the top deck and bottom deck for providing strength to the pallet assembly.

A method of forming a top frame, comprising:

• providing a pair of top frame members, each having a corresponding plurality of ribs defining a pair of cross-ribbed surfaces for mating with each other;
• introducing heat to the cross-ribbed surfaces to form mating plasticized surfaces;
• pressing the mating plasticized surfaces together;
• and
• cooling the mating plasticized surfaces forming a welded joint therebetween defining a plurality of box sections extending between the pair of top frame members.

A method of forming a top frame assembly, comprising:

• providing a first top frame member having a plurality of first cross-rib members projecting therefrom defining a plurality of partial upper box beam sections having a first mating surface;
• providing a second top frame member having a plurality of second cross-rib members projecting therefrom defining a plurality of partial lower box beam sections having a second mating surface corresponding to the first mating surface;
• and
• securely attaching the first mating surface to the second mating surface to define a plurality of whole box beam sections between the first top frame member and the second top frame member for providing strength to the top frame.

A method of forming a pallet, comprising:

• providing a first member having a first upper surface upon which the objects are placed, and a first lower surface defined by a plurality of downstanding cross-rib members;
• providing a second member having a second lower surface and a second upper surface defined by a plurality of upstanding cross-rib members corresponding to the downstanding cross-rib members of the first members;
• securely mounting the upstanding and downstanding cross-rib members of the first and second members to define a plurality of box beam sections therebetween;
• providing a third member having a third upper surface and a third lower surface defined by a plurality of downstanding cross-rib members, the third upper surface and the second lower surface having corresponding flanged surfaces;
• securely mounting the third upper surface and the second lower surface to each other to form a plurality of columns;
• providing a fourth member having a fourth upper surface defined by a plurality of upstanding cross-rib members corresponding to the downstanding cross-rib members of the third member and securely mounted therewith to define a plurality of box beam sections;
• and
• securely mounting the upstanding and downstanding cross-rib members of the third and fourth members to define a plurality of box beam sections therebetween.

A pallet assembly, comprising:

• a first pallet portion having a first pallet surface including a first plurality of cross-rib members;
• a second pallet portion disposed adjacent the first pallet portion and having a second pallet surface including a second plurality of cross-rib members corresponding to the first plurality of cross-rib members, the first and second plurality of cross-rib members being welded together to form a first pallet deck having a first plurality of box sections between the first and second pallet portions, the second pallet portion further including a mating surface opposite the second pallet surface;
• a third pallet portion disposed adjacent the second pallet portion and having a third pallet surface including a third plurality of cross-rib members, the third pallet portion having an other mating surface opposite the third pallet surface;
• and
• a fourth pallet portion disposed adjacent the third pallet portion and having a fourth pallet surface including a fourth plurality of cross-rib members corresponding to the third plurality of cross-rib members, the third and fourth plurality of cross-rib members being welded together to form a second pallet deck having a second plurality of box beam sections between the third and fourth pallet portions, wherein the mating surface of the second pallet portion and the other mating surface of the third pallet portion are welded together to define columns extending between the first pallet deck and second pallet deck.