Plastic pallet with sleeved reinforcing rods and associated method for making the same

<u>Field of the Invention</u>

0001The present invention relates to the field of pallets useful in material handling, and more particularly, to a multi-piece plastic pallet designed for use with forklift equipment.

<u>Background of the Invention</u>

0002Pallets are customarily used to transport and store goods. A pallet typically includes an upper deck and a lower deck separated by support blocks. Pallets have traditionally been formed of wood. While advantageous in terms of cost, wood pallets have many disadvantages. For example, they are subject to breakage and are therefore reusable only over a short period of time. Wooden pallets are also difficult to maintain in a sanitary condition, thereby limiting their usability in applications where sanitation is important, such as in food handling applications.

0003With the growth of the plastics industry a wide variety of plastics have been investigated to determine their suitability for use in producing pallets. Plastic pallets can easily be molded and are stronger and lighter weight than wooden pallets. They can also be made with recyclable materials. Furthermore, plastic pallets are more durable than wooden pallets. Documents <patcit id="pcit0001" dnum="US2003136314A"><text>US-A-2003 136314</text></patcit> regarded as the closest prior art discloses a plastic pallet with a lower and an upper deck, each having cooperating sleeves.

0004To increase the durability of plastic pallets, reinforcing elements or rods have been used. For example, <patcit id="pcit0002" dnum="US6199488B"><text>U.S. Patent No. 6,199,488</text></patcit> discloses a reinforced plastic pallet comprising an upper deck formed of a plastic material having a first coefficient of thermal expansion, and a lower deck formed of a plastic material having substantially the first coefficient of thermal expansion. The lower deck includes a plurality of channels formed in its upper surface, and a plurality of reinforcing elements having a second coefficient of thermal expansion different from the first degree of expansion are in the plurality of channels. The channels are provided with retainers to retain the reinforcing elements therein.

0005<patcit id="pcit0003" dnum="US5868080A"><text> U.S Patent No. 5,868,080</text></patcit> discloses a reinforced plastic pallet with reinforcing rods. At least some of the reinforcing rods have an exposed surface at a top surface of the pallet. In addition to functioning as a reinforcing member, the exposed surfaces of the reinforcing rods comprise an anti-skid surface for maintaining positioning of a payload on the pallet.

0006Yet another approach to increase the durability of plastic pallets is disclosed in <patcit id="pcit0004" dnum="US4735154A"><text>U.S. Patent No. 4,735,154</text></patcit>. The '154 patent provides a reinforced loading pallet comprising two essentially rectangular matching panels one superposed over the other, with each panel having a rigid frame including ties equipped with hollow, polygonal feet arranged at four outer corners of the frame. At least some of the ties in at least one of the frames are provided with channels, with at least some of the channels intersecting in a single plane. Rods are inserted into the channels for reinforcing the pallet.

0007While plastic pallets offer several advantages over wood pallets, there is still a demand to increase durability and strength of plastic pallets.

<u>Summary of the Invention</u>

0008In view of the foregoing background, an object of the present invention is to increase the durability of plastic pallets.

0009This and other objects, advantages and features in accordance with the present invention are to provide a plastic pallet comprising an upper and lower deck. A plurality of first joining members may project downwardly from the upper deck, with each first joining member including an outer sleeve. A plurality of second joining members may project upwardly from the lower deck, with each second joining member including an inner sleeve. At least one of the upper and lower decks may include a plurality of channels between top and bottom surfaces thereof, with each channel extending from a side edge to an opposing side edge of the corresponding deck.

0010A plurality of sleeved reinforcing rods may be in the plurality of channels. Each sleeved reinforcing rod may comprise a reinforcing rod having opposing ends and side surfaces therebetween, and a sleeve enclosing the side surfaces of the reinforcing rod. There is preferably relative movement between the sleeve and the reinforcing rod. The inner sleeves of the second joining may members receive the outer sleeves of the first joining members to define support blocks joining the upper and lower decks.

0011The channels may be in the lower deck only, in the upper deck only, or in both the upper and lower decks. When the sleeved reinforcing rods are in both decks, the sleeved reinforcing rods in the upper deck may be orthogonal to the sleeved reinforcing rods in the lower deck. All of the sleeved reinforcing rods in a same deck may be co-planar and parallel to one another.

0012The sleeved reinforcing rods are inserted into upper and/or lower deck molds before the upper and lower decks are formed. The sleeved reinforcing rods are thus insert molded. Plastic pallet manufacturers typically add reinforcing rods to a pallet after the pallet is formed. This requires the pallet to be molded first, and then add the reinforcing rods. In accordance with the present invention, the sleeved reinforcing rods are inserted into the pallet mold.

0013The plastic of the sleeve may have a melting point that is slightly higher than the melting point of the plastic used to form the upper and lower decks. As a result, the outside surface of the sleeves will partially melt or bond to the plastic of the upper and lower decks while still allowing movement of the reinforcing rods therein. Alternatively, the melting point of the sleeve may be the same as the melting point of the upper and lower decks, but cooling characteristics of the molten plastic during manufacturing may still result in the outside surface of the sleeves partially melting or bonding to the plastic of the upper and lower decks layers without melting down to the reinforcing rods.

0014Each reinforcing rod may be hollow so that an opening extends between the opposing open ends thereof. The plastic pallet may further comprise a plurality of end caps inserted into the open ends of the reinforcing rods. Each reinforcing rod may comprise fluorine-containing polymers to assist with the relative movement with its sleeve.

0015The upper deck may further include a plurality of snap-pin openings, with each outer sleeve projecting downwardly from the upper deck surrounding a respective snap-pin opening. Each second joining member projecting upwardly from the lower deck may include a snap-pin receiving cavity positioned therein. Snap-pins may be inserted may be into the snap-pin openings in the upper deck, with each snap-pin extending through the snap-pin receiving cavity for engaging a backside of the inner sleeve associated therewith.

0016Another aspect is directed to a method for making a pallet as described above. The method may comprise forming a plurality of sleeved reinforcing rods, with each sleeved reinforcing rod comprising a reinforcing rod having opposing ends and side surfaces therebetween, and a sleeve enclosing the side surfaces of the reinforcing rod. There is relative movement between the sleeve and the reinforcing rod. The method may further comprise providing respective molds for the upper and lower decks, and positioning the sleeved reinforcing rods in the respective decks. The upper and lower decks including their respective first and second joining members are formed. The inner sleeves of the second joining members may be positioned for receiving the outer sleeves of the first joining members to define the support blocks joining the upper and lower decks.

<u>Brief Description of the Drawings</u>

0017<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">FIG. 1</figref> is a top perspective view of an assembled pallet in accordance with the present invention.</li><li><figref idref="f0002">FIG. 2</figref> is a bottom perspective view of the pallet shown in <figref idref="f0001">FIG. 1</figref>.</li><li><figref idref="f0003">FIG. 3</figref> is a bottom perspective view of the upper deck of the pallet shown in <figref idref="f0001">FIG. 1</figref>.</li><li><figref idref="f0003">FIG. 4</figref> is a top perspective view of the lower deck of the pallet shown in <figref idref="f0001">FIG. 1</figref>.</li><li><figref idref="f0004">FIG. 5</figref> is a perspective view of a snap-pin used within each support block in accordance with the present invention.</li><li><figref idref="f0004">FIG. 6</figref> is a top view of the snap-pin shown in <figref idref="f0004">FIG. 5</figref>.</li><li><figref idref="f0004">FIG. 7</figref> is a partial cross-sectional side view of a pallet illustrating a snap-pin within a support block in accordance with the present invention.</li><li><figref idref="f0005">FIG. 8</figref> is a perspective view of the pallet unassembled in accordance with the present invention.</li><li><figref idref="f0006">FIG. 9</figref> is a perspective view of the pallet shown in <figref idref="f0005">FIG. 8</figref> assembled.</li><li><figref idref="f0007">FIG. 10</figref> is a side view of the pallet illustrating positioning of the channels in the upper deck in accordance with the present invention.</li><li><figref idref="f0007">FIG. 11</figref> is a side view of the pallet illustrating positioning of the channels in the lower upper deck in accordance with the present invention.</li><li><figref idref="f0007">FIG. 12</figref> is a cross-sectional view of a sleeved reinforcing rod in accordance with the present invention.</li><li><figref idref="f0008">FIG. 13</figref> is a flow chart illustrating a method for making a pallet in accordance with the present invention.</li></ul>

<u>Detailed Description of the Preferred Embodiments</u>

0018The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.

0019<figref idref="f0001 f0002 f0003">FIGS. 1-4</figref> illustrate top and bottom perspective views of a pallet <b>10</b> having upper and lower decks <b>12, 14</b> that are held together using snap-pins <b>16.</b> The upper deck <b>12</b> is also known as the cargo layer, and the lower deck <b>14</b> is also known as the base layer.

0020The upper deck <b>12</b> includes a plurality of first joining members that project downwardly from the upper deck, with each first joining member including an outer sleeve <b>40.</b> The lower deck <b>14</b> includes a plurality of second joining members that project upwardly from the lower deck, with each second joining member including an inner sleeve <b>42.</b> The inner sleeves <b>42</b> of the second joining members receive the outer sleeves <b>40</b> of the first joining members to define support blocks <b>18, 18a</b> joining the upper and lower decks <b>12, 14.</b>

0021The support blocks <b>18, 18a</b> define a space <b>20</b> between the upper and lower decks <b>12, 14</b> for receiving at least one lifting member, such as a tine of a pallet jack. An advantage of the snap-pins <b>16</b> is that they act as fusible links in the event a separation force is applied between the upper and lower decks <b>12, 14</b> of the pallet <b>10.</b> This separation force may result when the wheels of the pallet jack are resting on the lower layer <b>14,</b> and the tines extending from the pallet jack are lifted upwards. This causes the upper deck <b>12</b> to become separated from the support blocks <b>18, 18a.</b> The tabs <b>50</b> on the fusible links <b>16</b> will snap or break when the separation force becomes too excessive. Consequently, instead of replacing the entire upper deck <b>12,</b> the snap-pins <b>16</b> with the broken tabs <b>50</b> are replaced.

0022As will be discussed in greater detail below, the support blocks <b>18, 18a</b> are formed by the outer and inner sleeves <b>40, 42</b> extending from the respective upper and lower decks <b>12, 14.</b> The outer and inner sleeves <b>40, 42</b> are molded as part of their respective upper and lower decks <b>12, 14.</b> However, the upper and lower decks <b>12, 14</b> are separately molded.

0023The upper deck <b>12</b> includes a generally flat, planar surface having a plurality of holes <b>22</b> extending therethrough. Likewise, the lower deck <b>14</b> includes a generally flat, planar surface having a plurality of holes <b>23</b> extending therethrough. The holes <b>22, 23</b> provide several benefits including a reduced surface area of the upper and lower decks <b>12, 14,</b> increased air circulation for items placed on the upper deck, and a reduced weight of the pallet, for example. An example plastic pallet with upper and lower decks is disclosed in <patcit id="pcit0005" dnum="US20070256609A" dnum-type="L"><text>U.S. published patent application number 2007/0256609</text></patcit>. This patent is assigned to the current assignee of the present invention, and is incorporated herein by reference in its entirety.

0024The upper deck <b>12</b> may include an outer perimeter <b>24</b> of the planar surface that does not include any holes <b>12.</b> This area may be about 3 to 5 inches wide, for example. The lower deck <b>14</b> has a perimeter shape that substantially matches the perimeter shape of the upper deck <b>12.</b> The lower deck <b>14</b> may include a rectangular perimeter shape having cross members <b>26, 28</b> that intersect a center portion of each side of the rectangular perimeter, midway between the corners of the pallet <b>10.</b>

0025The upper and lower decks <b>12,14</b> may be molded from thermoplastic or other polymer materials, including high density polyethylene (HDPE), polypropylene (PP), among other polymer materials. As may be appreciated by those skilled in the art, the polymer materials may be filled or unfilled and/or may include particulate or fibrous, natural or synthetic materials, among other features. For example, unfilled HDPE may provide improved impact strength, PP having strengtheners (i.e., long glass fibers) may provide improved structural properties, and unfilled PP with random copolymers may provide improved reinforcement qualities.

0026The upper and lower decks <b>12, 14</b> may be molded from different thermoplastics or polymer materials. For example, the upper deck <b>12</b> may be molded from a first type of thermoplastic or polymer material, while the lower deck <b>12</b> may be molded from a second type of thermoplastic or polymer material. According to alternative embodiments, all or a portion of the upper and lower decks <b>12, 14</b> may be constructed from materials other than plastic, such as wood and/or metal, for example.

0027The illustrated pallet <b>10</b> is substantially square-shaped. An example size of the pallet <b>10</b> is 48 inches by 48 inches, for example. As readily appreciated by those skilled in the art, the pallet <b>10</b> may also be formed with other rectangular shapes, such as 40 inches by 48 inches, for example. The pallet <b>10</b> may include rounded corners/edges <b>30</b> along the perimeter thereof. Rounded corners/edges <b>30</b> help to reduce and/or deflect damage during impact with the tines of a forklift, as well as providing an improved aesthetic appearance.

0028The illustrated pallet <b>10</b> includes a plurality of support blocks <b>18, 18a</b> that are provided to join the upper and lower decks <b>12, 14</b> together as well as providing separation so that the tines of a pallet jack can be inserted therebetween. For example, the illustrated pallet <b>10</b> includes nine support blocks <b>18, 18a</b> that are located at the corners of the pallet, as well as between the corners of the pallet along the outer edges of the pallet. A support block <b>18a</b> is also provided in a center of the pallet <b>10</b> at the intersection of cross members <b>26, 28</b> in the lower deck <b>14.</b>

0029Each support block <b>18</b>, <b>18a</b> is defined by an outer sleeve <b>40</b> projecting downwardly from the upper deck <b>12</b> and an inner sleeve <b>42</b> projecting upwardly from the lower deck <b>14.</b> The outer and inner sleeves <b>40, 42</b> are molded with their respective upper and lower decks <b>12, 14.</b> The outer and inner sleeves <b>40, 42</b> are sized so that they overlap one another when joined together. The shapes of the outer and inner sleeves <b>40, 42</b> are not limited to any particular shape. The outer and inner sleeves <b>40, 42</b> may be square-shaped, triangular-shaped, oval-shaped or cross-shaped, for example. The edges of the outer sleeves <b>40</b> may be rounded.

0030The upper deck <b>12</b> includes a plurality of snap-pin openings for receiving the snap-pins <b>16.</b> Each outer sleeve <b>40</b> surrounds a respective snap-pin opening. The lower deck <b>14</b> includes a snap-pin receiving cavity <b>44</b> positioned within each inner sleeve <b>42.</b> A plurality of radial ribs <b>43</b> extending between the snap-pin receiving cavity <b>44</b> and the inner sleeve <b>42.</b>

0031An advantage of the support blocks <b>18, 18a</b> is that the impact energy from contact with the tines of the forklift can be dissipated among the following elements: the outer sleeve <b>40,</b> the inner sleeve <b>42,</b> the radial ribs <b>43</b> and the cylindrical core defined by the snap-pin receiving cavity <b>44</b> in the inner sleeve. The fork tines strike the outer sleeve <b>40</b> first, which absorbs most of the impact energy. The impact energy may then be transmitted to the inner sleeve <b>42,</b> which also absorbs some of the impact energy. More absorption of the impact energy takes place at the radial ribs <b>43.</b> The remaining impact energy reaches the snap-pin receiving cavity <b>44</b> for dissipation.

0032Each snap-pin <b>16</b> includes a head <b>46,</b> a body <b>48</b> and spaced apart tips <b>50,</b> as best illustrated in <figref idref="f0004">FIG. 5</figref>. The head <b>46</b> is for engaging a snap-pin opening in the upper deck <b>12.</b> The head <b>46</b> of each snap-pin <b>16</b> may be shaped to include spaced apart straight edges <b>49,</b> as illustrated in <figref idref="f0004">FIG. 6</figref>. Each snap-pin opening in the upper deck <b>12</b> is correspondingly shaped the same. This helps to hold the snap-pins <b>16</b> in place. The snap-pins <b>16</b> are typically inserted into the pallet <b>10</b> after the upper and lower decks <b>12, 14</b> have been joined together to form the support blocks <b>18, 18a.</b>

0033The spaced apart tips <b>50</b> extend through the snap-pin receiving cavity <b>44</b> for engaging a backside <b>50</b> of the inner sleeve, as best illustrated in <figref idref="f0004">FIG. 7</figref>. The snap-pin receiving cavity <b>44</b> does not extend all the way from the top of the inner sleeve <b>42</b> to the bottom of the lower deck <b>14.</b> This is to allow room for the tabs <b>50</b> on the snap-pin <b>16</b> to clear and engage the backside <b>60</b> of the inner sleeve <b>42.</b>

0034Even though the upper and lower decks <b>12, 14</b> are separated in <figref idref="f0003">FIGS. 3 and 4</figref>, the snap-pins <b>16</b> are positioned accordingly for illustration purposes. As illustrated in <figref idref="f0003">FIG. 3</figref>, the snap-pins <b>16</b> extend within and past the outer sleeves <b>40.</b> As illustrated in <figref idref="f0003">FIG. 4</figref>, the heads <b>46</b> of the snap-pins <b>16</b> are raised above the inner sleeve <b>42</b> and the snap-pin receiving cavities <b>44</b> without the lower deck <b>14</b> in place. This allows clearance for the head <b>46</b> of each snap-pin <b>16</b> to engage a snap-pin opening in the upper deck <b>12,</b> while the spaced apart tips <b>50</b> extend through the snap-pin receiving cavity <b>44</b> for engaging a backside <b>60</b> of the inner sleeve <b>42</b> associated therewith.

0035The spaced apart tips <b>50</b> of each snap-pin <b>16</b> resiliently extend outwards from the body <b>48</b> after having passed through the snap-pin receiving cavity <b>44</b> for engaging the backside <b>50</b> of the inner sleeve <b>42</b> associated therewith. The spaced apart tips <b>50</b> of each snap-pin <b>16</b> may be angled to facilitate insertion thereof through the snap-pin receiving cavity <b>44.</b> The spaced apart tips <b>50</b> of each snap-pin comprise a respective lip <b>51</b> for engaging the backside of the inner sleeve. The respective lips <b>51</b> are configured to break off based on an excessive separation force applied between the upper and lower decks <b>12, 14.</b> The snap-pins <b>16</b> are also formed out of plastic. Alternatively, the snap-pins <b>16</b> may be formed out any of the materials used to form the upper and lower decks <b>12, 14</b> as discussed in detail above.

0036Another aspect is directed to improving the durability of the pallet. This is accomplished by inserting sleeved reinforcing rods <b>80'</b> into the upper and/or lower molds of the pallet <b>10'</b> for the respective upper and/or lower decks <b>12', 14'.</b> As readily appreciated by those skilled in the art, the sleeved reinforcing rods 80' are insert molded.

0037As best illustrated by the exploded view of the pallet <b>10'</b> in <figref idref="f0005">FIG. 8</figref>, four sleeved reinforcing rods <b>80'</b> are used in the lower deck <b>14',</b> and four sleeved reinforcing rods <b>80'</b> are used in the upper deck <b>12'.</b> The actual number of sleeved reinforcing rods <b>80' will</b> vary depending on the size of the pallet <b>10'</b> and its intended use, as well as on the actual number of support blocks <b>18', 18a'.</b> As noted above, the sleeved reinforcing rods <b>80'</b> may be in the lower deck <b>14'</b> only, in the upper deck <b>12'</b> only, or in both the upper and lower decks. For illustration purposes, both the upper and lower decks <b>12', 14'</b> include sleeved reinforcing rods <b>80'.</b> The assembled pallet <b>10'</b> is illustrated in <figref idref="f0006">FIG. 9</figref>.

0038The upper deck <b>12'</b> includes channels <b>92</b> between its top and bottom surfaces <b>94', 96',</b> as illustrated in <figref idref="f0007">FIG. 10</figref>. The upper surface of the sleeved reinforcing rod <b>80'</b> is below the top surface <b>94'</b> of the upper deck <b>12',</b> and is above the bottom surface <b>96'</b> of the upper deck <b>12'.</b> Each channel <b>92'</b> extends from a side edge to an opposing side edge of the upper deck <b>12'.</b>

0039Similarly, the lower deck <b>14'</b> includes channels <b>102'</b> between its top and bottom surfaces <b>104', 106',</b> as illustrated in <figref idref="f0007">FIG. 11</figref>. The upper surface of the sleeved reinforcing rod <b>80'</b> is below the top surface <b>104'</b> of the lower deck <b>14',</b> and is above the bottom surface <b>106'</b> of the lower deck <b>14'.</b> Each channel <b>102'</b> extends from a side edge to an opposing side edge of the lower deck <b>12'.</b>

0040The illustrated channels <b>92', 102'</b> are positioned so that they are on top or bottom of the support blocks <b>18', 18a'.</b> The center support blocks <b>18a'</b> may be wider than the other support blocks <b>18'</b> so that the two sleeved reinforcing rods <b>80'</b> in the channels <b>92'</b> in the center portion of the upper deck <b>12'</b> and the two sleeved reinforcing rods <b>80'</b> in the channels <b>102'</b> in the center portion of the lower deck <b>14'</b> can each be supported by a support block yet still provide strength to the upper and lower decks. Alternatively, all of the support blocks <b>18', 18a'</b> are the same size.

0041Referring now to <figref idref="f0007">FIG. 12</figref>, a sleeved reinforcing rod <b>80'</b> comprises a reinforcing rod <b>82'</b> having opposing ends and side surfaces therebetween, and a sleeve <b>84'</b> enclosing the side surfaces of the reinforcing rod. The ends of the reinforcing rod <b>82'</b> are exposed. The sleeved reinforcing rod <b>80'</b> allows relative movement between the sleeve <b>84'</b> and the reinforcing rod <b>82'.</b>

0042The reinforcing rod <b>82'</b> is made of metal, for example, and the sleeve <b>84'</b> is made of plastic, for example. The metal may comprise steel. However, other types of metals may be used. Alternatively, the reinforcing rod <b>82'</b> may comprise non-metal materials, such as reinforced fiberglass, for example.

0043As the pallet <b>10'</b> is flexed or as the metal contracts, relative movement is needed between the reinforcing rod <b>82'</b> and the plastic sleeve <b>84'.</b> Consequently, the reinforcing rod <b>82'</b> is simply not coated in plastic. Otherwise, the local plastic around the reinforcing rod <b>82'</b> can be over stressed, resulting in cracks.

0044The illustrated reinforcing rod <b>82'</b> has a rectangular shape, and is hollow so that an opening extends between the opposing ends thereof. In one embodiment, the sleeve <b>84'</b> is extruded over the reinforcing rod <b>82'</b> to form the sleeved reinforcing rod <b>80'.</b> The shape of the reinforcing rod <b>82'</b> may vary, and may even be filled in other embodiments. To assist with the relative movement between the reinforcing rod <b>82'</b> and the sleeve <b>84',</b> the reinforcing rod may comprise fluorine-containing polymers. Fluorine-containing polymers are also known as Teflon^®, and includes the following: polytetrafluoroethylene (PTFE), perfluoroalkoxy (PFA) and fluorinated ethylene proplene (FEP).

0045Plastic pallet manufacturers typically add reinforcing rods to a pallet after the pallet is formed, as is the case for the prior art patents discussed in the background section. This requires the pallet to be molded first, and then add the reinforcing rods. In sharp contrast, the sleeved reinforcing rods <b>80'</b> are inserted into the pallet mold before the upper and lower decks <b>12', 14'</b> are formed therein.

0046The plastic of the sleeve <b>84'</b> has a melting point that is slightly higher than the melting point of the plastic used to form the upper and lower decks <b>12', 14'.</b> As a result, the outside surface of the sleeves <b>84'</b> will partially melt or bond to the plastic of the upper and lower decks <b>12', 14'</b> while still allowing movement of the reinforcing rods <b>82'</b> therein. Alternatively and not covered by the invention as recited in the claims, the melting point of the sleeve <b>64'</b> is the same as the melting point of the upper and lower decks <b>12', 14',</b> but cooling characteristics of the molten plastic during manufacturing still results in the outside surface of the sleeves <b>84'</b> partially melting or bonding to the plastic of the upper and lower decks <b>12', 14'</b> without melting down to the reinforcing rods <b>82'.</b>

0047After the upper and lower decks <b>12', 14'</b> have been formed with the sleeved reinforcing rods <b>80'</b> therein, end caps <b>90'</b> are used to enclose the ends of the reinforcing rods <b>82'.</b> Alternatively, the ends of the sleeved reinforcing rods <b>80'</b> may be closed as a result of being formed. If a plastic pallet <b>10'</b> is to be recycled, , the ends of the sleeve <b>84'</b> are punctured or the end caps <b>90'</b> are removed so that the reinforcing rod <b>82'</b> can be removed therefrom for use in another pallet.

0048The upper and lower decks <b>12', 14'</b> include additional holes <b>71', 73'</b> for exposing the sleeved reinforcing rods <b>80'.</b> This also allows the sleeves <b>84'</b> to be punctured from the side to help in removing the reinforcing rods <b>82'</b> therefrom.

0049The illustrated pallet <b>10'</b> further includes friction plugs <b>110'</b> to prevent a load from sliding over the top surface <b>94'</b> of the upper deck <b>12'.</b> The friction plugs <b>110'</b> are inserted through corresponding openings in the upper deck <b>12'</b> after the pallet <b>10'</b> has been formed.

0050Another aspect is directed to a method for making a pallet <b>10'</b> as described above. Referring now to the flow chart illustrated in <figref idref="f0008">FIG. 13</figref>, the method comprises from the start (Block <b>120),</b> forming at Block <b>122</b> a plurality of sleeved reinforcing rods <b>80',</b> with each sleeved reinforcing rod comprising a reinforcing rod <b>82'</b> having opposing ends and side surfaces therebetween, and a sleeve <b>84'</b> enclosing the side surfaces of the reinforcing rod. There is relative movement between the sleeve <b>84'</b> and the reinforcing rod <b>82'.</b>

0051The method further comprises providing respective molds for the upper and lower decks <b>12', 14'</b> at Block <b>124,</b> and positioning the sleeved reinforcing rods <b>80'</b> in the respective decks at Block <b>126.</b> The upper and lower decks <b>12', 14'</b> including their respective first and second joining members <b>40', 42'</b> are formed at Block <b>128.</b> The inner sleeves of the second joining members <b>42'</b> are positioned at Block <b>130</b> for receiving the outer sleeves of the first joining members <b>40'</b> to define the support blocks <b>18', 18a'</b> joining the upper and lower decks <b>12', 14'.</b> The method ends at Block <b>132.</b>

0052Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included as readily appreciated by those skilled in the art.