ES2770632T3 - Single pallet top deck plastic pallet with inserts in it and related method - Google Patents

Abstract

A plastic pallet (20) comprising: a load layer (30) comprising a pair of external plastic pallet boards (32) positioned horizontally and at least one intermediate plastic pallet board (36) positioned horizontally between them , said at least one intermediate plastic deck board (36) having horizontally positioned opposite side walls (37) and a plurality of spaced openings (38) extending at least partially through the opposite side walls, and said pair having of external plastic pallet boards (32) horizontally placed opposite internal and external side walls (33 (1), 33 (2)), so that the external side wall (33 (2)) is closed, and a plurality of separate openings (34) extending through the inner side wall (33 (1)) and not extending through the outer side wall (33 (2)) of each outer plastic deck board (32), being aligned the plurality of spaced openings (34) in the inner side wall (33 (1)) of each outer plastic deck board (32) positioned horizontally with the plurality of spaced openings (38) in an adjacent side wall (37) of said at least an intermediate plastic pallet board (36) positioned horizontally; a plurality of inserts (60) in the plurality of spaced openings (34, 38); a base layer (50) comprising a plurality of plastic deck boards (50 (1), 50 (2), 50 (3)) positioned horizontally orthogonal to said pair of external plastic deck boards (32) positioned horizontally already said at least one intermediate plastic pallet board (36) horizontally placed on said load layer (30); and a plurality of separate support structures (40) coupled between said base and load layers (30, 50) and forming spaces between them to receive a lifting member.

Description

DESCRIPTION

Single layer top deck plastic pallet with inserts on it and related method

Field of the invention

The present invention relates to the field of pallets, and more particularly, to a plastic pallet accessible from all four sides with a sufficient bearing capacity and to related methods for making the same.

Background of the invention

Conventional pallets are generally made of wood and include a base layer and a load layer separated by support blocks. Base and load layers are also called bottom and top decks. Traditionally, the base and load layers are multiple layers, with each layer, respectively, having final deck boards assembled into connector boards running the entire length or width of the pallet. The final deck boards are nailed through the connector boards into the support blocks to build the primary pallet structure. The final deck boards are also known as main boards. Intermediate deck boards are placed between the end deck boards.

To move the loaded pallet on it, the teeth of a forklift or pallet truck are inserted into the spaces between the base and load layers on one main board side of the pallet. If the teeth were inserted into the gaps on a non-main board side of the pallet, the pallet would likely be overloaded if the load placed on it is relatively heavy, resulting in potential damage or weakening of the pallet.

In large open areas, maneuvering a forklift or pallet truck so that the tines can enter the gaps between the base and load layers on the main board side of the pallet is relatively straightforward. However, maneuvering such a lifting device becomes much more cumbersome in confined areas as the pallet can only be accessed from 2 different sides.

Even if conventional pallets are downsized from full size to half size or quarter size, there may still be difficulty in maneuvering the lifting device as the pallet can only be accessed from 2 different sides. For example, a confined area can be a display or display plant within a store. Instead of removing the load from the pallets, the load remains on the pallet for customers to see.

Consequently, there is a need for a pallet that can be accessed from all four sides. Since the load to be carried on the upper deck can sometimes be relatively heavy, the load carrying capacity of the pallet should not be sacrificed while providing accessibility.

One approach for such a pallet is disclosed in US Patent No. 4,834,001. The pallet has a base member provided with recesses for the teeth of a lifting device. The base member also includes a series of holes perpendicular to its longitudinal direction through which tubes can be inserted to join the base members together to form the pallet.

United States Patent No. 5,402,735 discloses a pallet that includes a plurality of skids. Each skid defines an upper load bearing surface, an opposite lower surface in which a tongue locating channel is formed, and a pair of opposite side surfaces. Through each side surface a predetermined number of bar locating openings has been formed. A plurality of bars are uniquely sized for the individual load to be handled. The bars are insertably received by a respective bar locating opening of an individual skid. At least one stabilizer has a main body and a predetermined number of tab members integrated with the main body of the stabilizer. Each tongue member is received by the tongue locating channel of an individual skate.

Still another approach is disclosed in US Patent No. 6,112,673 which provides a pallet assembly comprising a first rail member and a second rail member separate from the first rail member. At least one hollow tube member extends between the first rail member and the second rail member with a sheet member positioned on the tube member. A rod is placed within each tube member and extends through the first rail member and the second rail member. A clamping mechanism is associated with each rod to releasably clamp the first rail member to the second rail member, and to releasably clamp each hollow tube member and sheet member between the first rail member and the pallets. described, there is still a need to improve such pallets.

FR1173326A discloses a pallet and a pallet manufacturing method. The pallet comprises a load layer having a plurality of pallet boards, a base layer having a plurality of pallet boards, and a plurality of separate support structures. The deck boards of the load-bearing layer comprise a plurality of openings extending between the opposite side walls of the deck boards, into which inserts are inserted into said openings.

Document DE9411879U1 discloses a pallet for accommodating several boxes of drinks, the boxes being separated from each other.

US3513786A discloses a multi-section shelf and support assembly comprising support members, brackets, a multi-section shelf including separate segments, and means for holding the segments in separate relationship.

Document EP0727360A2 discloses a transport pallet comprising a wooden pallet frame covered on all sides by a plastic coating.

US 2007/0017423 A1 A1 discloses a pallet having a first deck, a second deck, and a plurality of composite block members that secure the first and second deck to each other to form a pallet.

Document WO 2013/135591 A1 discloses a transport pallet comprising a plurality of boards and blocks, having a core, each core being surrounded by a wrapper.

US 2011/0303128 A1 discloses a pallet featuring a floating, three-dimensional inductor body with improved load bearing capabilities.

Summary of the invention

The present invention is defined by a plastic pallet and a method of making a pallet as defined by independent claims 1 and 4, respectively. The embodiments are defined by the dependent claims.

In view of the above background, an object of the present invention is therefore to provide a pallet that can be accessed from all four sides without sacrificing its bearing capacity.

This and other objects, features and advantages in accordance with the present invention are provided by a plastic pallet comprising a load layer comprising a pair of horizontally positioned external plastic pallet boards and at least one intermediate plastic pallet board. placed horizontally between them. The at least one horizontally positioned intermediate plastic deck board has opposite side walls and a plurality of spaced apart openings that extend at least partially through the opposite side walls. The pair of horizontally placed outer plastic deck boards have opposite inner and outer side walls, so that the outer side wall is closed, and a plurality of separate openings that extend through the inner side wall and do not extend through of the outer side wall of each outer plastic deck board. The plurality of spaced openings in the side walls of each horizontally placed outer plastic pallet board are aligned with the plurality of spaced openings in an adjacent side wall of the at least one horizontally placed intermediate plastic pallet board. In the plurality of spaced openings there are a plurality of inserts.

A base layer comprises a plurality of horizontally positioned plastic pallet boards orthogonal to the pair of horizontally positioned outer plastic pallet boards and to the at least one horizontally positioned intermediate plastic pallet board in the load-bearing layer. A plurality of separate support structures are engaged between the base and load layers and form spaces between them to receive a lifting member.

Each insert may be orthogonal to the pair of horizontally positioned external plastic pallet boards and to the at least one horizontally positioned intermediate plastic pallet board on the load layer. Each insert can comprise a metal tube or a solid rod, for example.

The load layer is therefore a single layer top deck with inserts in it. Since the inserts and boards in the base layer are orthogonal to the boards in the load layer, this allows the pallet to have a high bearing capacity / resistance to transfer, while allowing accessibility from all 4 sides. The pallet is not limited to any particular size, and can be configured as a full-size, a half-size, or a quarter-size pallet, for example.

In one embodiment, the plurality of spaced openings that extend at least partially through the opposing side walls of the at least one horizontally positioned intermediate plastic deck board may include a first aperture that partially extends through one of the side walls and a second opening partially extending through the other side wall. The first and second partially extending openings may be aligned and in contact with each other to form a continuous opening therethrough. The plurality of inserts may comprise a single insert that extends between the openings in the pair of horizontally positioned external plastic deck boards and through the continuous opening in the at least one horizontally placed intermediate plastic pallet board.

In another embodiment, the first and second partially extending openings in the at least one horizontally positioned intermediate plastic pallet board are aligned but not in contact with each other. The plurality of inserts may comprise separate inserts extending between the openings in the horizontally positioned pair of external plastic deck boards and the first and second partially extending openings in the at least one horizontally positioned intermediate plastic deck board.

In yet another embodiment, the first and second partially extending openings in the at least one horizontally positioned intermediate plastic deck board are not aligned and do not extend through the opposite side wall. The plurality of inserts may comprise separate inserts extending between the openings in the horizontally positioned pair of external plastic deck boards and the first and second partially extending openings in the at least one horizontally positioned intermediate plastic deck board.

The pair of horizontally placed outer plastic deck boards and the at least one horizontally placed intermediate plastic deck board may have a thickness T, and wherein the outer diameter of each insert is within a range of 0.25T and 0.75TH. For example, T can be equal to 2.54 cm (1 inch), and wherein the outer diameter of each insert is within a range of 0.635 - 1.905 cm (0.25 and 0.75 inches).

Each insert may overlap a respective horizontally placed plastic deck board on the base layer. Each support structure may be C or U-shaped. The pallet may further comprise a plurality of fasteners that couple the base and load layers to the plurality of separate support structures.

Another aspect is directed to a method of making a pallet as described above.

Brief description of the drawings

Figure 1 is a top perspective view of a pallet with a single layer top deck having inserts thereof in accordance with the present invention.

Figure 2 is a bottom perspective view of the pallet shown in Figure 1.

Figure 3 is a top plan view of the pallet shown in Figure 1.

Figure 4 is a side view of the pallet shown in Figure 1.

Figure 5 is a rear view of the pallet shown in Figure 1.

Figure 6 is a top plan view of the loading layer without the inserts in accordance with the present invention. Figure 7 is a side perspective view of an insert for the loading layer shown in Figure 6.

Figure 8 is a side view of an intermediate deck board with an insert therein in accordance with the present invention.

Figure 9 is a perspective side view of an alternative embodiment of the insert shown in Figure 7. Figure 10 is a perspective side view of yet another alternative embodiment of the insert shown in Figure 11 is a bottom perspective view of another embodiment of the pallet shown in figure 1 with a non-centered base layer.

Figure 12 is a side view of the pallet shown in Figure 11 nested or stacked with another pallet.

Figures 13-15 are top plan views of different embodiments of the loading layer showing different positions for the apertures receiving inserts in accordance with the present invention.

Figure 16 is a flow chart illustrating a method for making a pallet in accordance with the present invention. Figure 17 is a side view of an intermediate plastic deck board with a layer of fire retardant material thereon in accordance with the present invention.

Figure 18 is a cross-sectional side view of an intermediate plastic pallet board with a layer of flame retardant material integrated therein in accordance with the present invention.

Detailed description of the preferred embodiments

The present invention will now be described in greater detail hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention can, however, be carried out in many different ways and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be comprehensive 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 notations are used to indicate like elements in alternate embodiments.

Referring initially to Figures 1-5, the illustrated pallet 20 includes a load-bearing layer 30, a base layer 50, and support structures 40 between them. The load layer 30 is a single layer top deck with inserts 60 therein. The inserts 60 and the boards in the base layer 50 are orthogonal to the boards in the load layer 30. This allows the pallet 20 to have a high handling capacity / resistance to transfer, while allows accessibility from all four sides. Pallet 20 is not limited to any particular size, and can be configured as a full-size, a half-size, or a quarter-size pallet. For purposes of discussion, the pallet 20 illustrated is a medium-sized pallet, ie 40 inches by 24 inches.

More particularly, the load layer 30 comprises a pair of horizontally positioned outer deck boards 32 and at least one intermediate deck board 36 positioned horizontally between them. In the illustrated embodiment, there are a pair of intermediate deck boards 36.

Each horizontally positioned intermediate deck board 36 has opposing side walls 37 and a plurality of spaced openings 38 extending through the opposing side walls, as best illustrated in Figure 6. Similarly, each outer deck board 32 positioned horizontally, it has opposing inner and outer side walls 33 (1), 33 (2), and a plurality of spaced openings 34 extending through inner side walls 33 (1). The corresponding opposite portions of the outer side walls 33 (2) are closed. Consequently, apertures 34 terminate within each end deck board 32 below opposite portions of outer side wall 33 (2).

The spaced openings 34 in the pair of horizontally placed outer deck boards 32 are aligned with the spaced openings 38 in each horizontally placed intermediate deck board 36.

Inserts 60 are inserted into openings 34, 38. For the illustrated pallet 20, there are three inserts 60.

Each insert 60 can be an open tube, for example, as illustrated in Figure 7. The tube can be made of metal or galvanized steel, for example. According to one example, a diameter of the insert 60 is selected based on the thickness of the boards 32, 36 in the load layer 30 to provide greater resistance to racking for the pallet 20.

As illustrated in Figure 8, the thickness of the boards 32, 36 is represented by T, where the outer diameter of each insert 60 is preferably within a range of 0.25T and 0.75T. For example, the thickness of each board 32, 36 is approximately 2.54 cm (1 inch), where the diameter of insert 60 is within a range of approximately 0.635 and 1.905 cm (0.25 - 0.75 inches). ). In one embodiment, insert 60 has an outside diameter of 1.5875 cm (5/8 inches) and an inside diameter of 0.9525 cm (3/8 inches). With this particular combination of insert size and pallet board thickness, the racking resistance of the half pallet 20 is approximately 1400 pounds.

Alternatively, the insert may be a solid rod 60 ', as illustrated in FIG. 9. In yet another embodiment, insert 60 "is a spring pin as illustrated in FIG. 10. Spring pin 60" has an opening 61 "along its longitudinal length. Spring pin 60 "is bent to fit within respective openings 34, 38. Once inserted, the spring 60 "expands to hold the deck boards 32, 36 in place.

Base layer 50 includes a plurality of deck boards 50 (1), 50 (2), 50 (3) positioned horizontally orthogonal to the pair of external deck boards 32 positioned horizontally and to each intermediate deck board 36 positioned horizontally in the load layer 30. Base layer 50 does not include any deck boards that extend in the same direction as deck boards 32, 36 in load layer 30. The lack of base layer 50 which does not include boards Platform boards orthogonal to the illustrated platform boards 50 (1), 50 (2), 50 (3) advantageously reduce the weight and cost of the pallet 20 without affecting its handling capacity.

In the illustrated pallet 20, there are nine separate support structures 40 coupled between the base and load layers 30, 50. Each support structure 40 is made of metal and is "C" or "U" shaped. The support structures 40 allow spaces to be formed to receive the teeth of a lift member from either side of the pallet 20. Alternatively, any one or all of the illustrated support structures 40 may have a different shape and composition. For example, the middle support blocks that come into contact with the intermediate deck boards 36 can be square wooden blocks.

To secure the deck boards 32, 36 on the load layer 30 to the support structures 40, fasteners 70 are used. The fasteners 70 can be threaded bolts or rivets, for example. If the support structures 40 were formed of wood, for example, the fasteners would be nails or screws, for example. Preferably, the top surface of each clip 70 is recessed or flush with the exposed outer surface of each deck board 32, 36. Similarly, clips 70 are used to secure deck boards 50 (1), 50 (2). ), 50 (3) in the base layer 50 to the support structures 40.

The illustrated pallet 20 is a self-reinforcing pallet in the sense that no fasteners are needed for the inserts 60 as they snap fit into their respective openings 34 and 38, and that the upper deck boards 32, 36 and the deck boards Lower 50 (1) -50 (3) are coupled to support structures 40 orthogonally. This configuration advantageously allows a strong pallet 20 that is light and relatively easy to access with a lifting device.

As illustrated in the figures, each insert 60 overlaps a respective horizontally positioned deck board 50 (1) -50 (3) on the base layer 50. As an alternative embodiment, instead of three lower deck boards 50 (1) -50 (3) regularly spaced, there are two deck boards 50 (1) ', 50 (2)' as illustrated in figure 11. The middle deck board 50 (2) 'is no longer in the center of pallet 20 ', but is offset to the location where the third deck board was initially located.

This particular configuration allows two pallets 20 'to be nested or stacked when not in use. As illustrated in Figure 12, the lower deck boards 50 (1) ', 50 (2)' for each pallet 20 'are adjacent to each other, with the load layers 30' being the outermost exposed surfaces.

The inserts 60 'may be in their original position as for the embodiment illustrated in Figures 1-5. Alternatively, the center insert 60 'is also offset to overlap the lower deck board 50 (2)'.

Alternative embodiments of the loading layer will now be discussed with reference to Figures 13-15. In one embodiment, the openings 34 ', 38' at the opposite edges of the pallet 20 'are the same as illustrated above, such that a single insert 60' extends between the openings 34 ', 38' in the pair of boards. external deck boards 32 'positioned horizontally and through the continuous opening in the at least one intermediate deck board 36' positioned horizontally, as illustrated in Figure 13. However, the additional openings 41 ', 43' within the pallet 20 'are staggered and only partially extend through the horizontally positioned intermediate deck board 36'.

The spaced openings 41 ', 43' in the horizontally positioned intermediate deck board 36 'include a first opening 43 (1)' which extends partially through one of the side walls and a second opening 43 (2) 'which extends extends partially through the other side wall. The partially extending openings 43 (1) ', 43 (2)' are not aligned and do not extend through the opposite side wall. In this embodiment, the spaced inserts extend between the openings 41 'in the pair of horizontally positioned external deck boards and the first and second openings 43 (1)', 43 (2) 'that partially extend into the deck board. intermediate 36 'placed horizontally.

In yet another embodiment, the openings 34 ", 38" in the pallet 20 "are aligned but do not contact each other within the horizontally positioned intermediate deck board 36", as illustrated in FIG. 14 In this embodiment, the inserts comprise separate inserts extending between the openings 34 "in the pair of horizontally positioned external deck boards 32" and the first and second openings 38 (1) ", 38 (2)". which partially extend into the horizontally positioned intermediate deck board 36 ''.

In yet another embodiment, the openings 34 '", 38"' and 41 "', 43 (1)"' and 41 "', 43 (2)"' in pallet 20 "'are not aligned within pallet 20" ', as illustrated in Figure 15. Rather, each of the openings are staggered relative to one another. A flow chart 100 illustrating a method for making a pallet 20 will now be discussed with reference to Figure 16. From the start (Block 102), the method comprises forming a load layer 30 on Block 104 comprising a pair of external deck boards 32 positioned horizontally and at least one intermediate deck board 36 positioned horizontally between them.

The at least one horizontally positioned intermediate deck board 36 is formed in Block 106 to have opposing side walls 37 and a plurality of spaced openings 38 extending through the opposing side walls. The pair of horizontally placed outer deck boards 32 is formed in Block 108 to have opposite side walls 33 (1) and 33 (2), and a plurality of spaced openings 34 extending through inner side wall 33 ( 1) of each external platform table. The plurality of spaced openings 34 in the pair of horizontally positioned outer deck boards 32 are aligned in Block 110 with the plurality of spaced apertures 38 in the at least one horizontally positioned intermediate deck board 36 to form a plurality of separate sets of aligned insert openings extending into loading layer 30.

The method further comprises inserting a plurality of inserts 60 into the plurality of separate sets of aligned insert openings in Block 112. Base layer 50 is formed in Block 114 to comprise a plurality of deck boards 50 (1) - 50 (3) positioned horizontally orthogonal to the pair of external platform boards 32 positioned horizontally and the at least one intermediate platform board 36 positioned horizontally in the load layer 30. The method further comprises in Block 116 coupling a plurality of structures of spaced support 40 between the base and load layers 50, 30 and to form spaces between them to receive a lifting member. The method ends at Block 118.

Some or all of the pallet boards on pallet 20 can be molded from thermoplastic or other polymeric materials, including high-density polyethylene (HDPE), polypropylene (PP), among other polymeric materials.

As will be appreciated by those skilled in the art, polymeric materials can be filled or unfilled and / or can include particulate or fibrous materials, natural or synthetic, among other characteristics. For example, unfilled e1HDPE can provide improved impact resistance, PP with strengtheners (e.g. long or short glass fibers, impact modifiers, or performance enhancing additives) can provide improved structural properties, and unfilled PP with random copolymers can provide improved reinforcing qualities.

The base and filler layers 50, 30 can be molded from different thermoplastic or polymeric materials. For example, the filler layer 30 can be molded from a first type of thermoplastic or polymeric material, while the base layer 50 can be molded from a second type of thermoplastic or polymeric material.

In addition, the plastic for the pallet 20 described above can be fire retardant. In one embodiment, a flame retardant material provides a protective layer or covering 120 for the plastic deck boards, as illustrated in Figure 17 for the intermediate plastic deck board 36. In another embodiment, the flame retardant material 122 is mixed with the plastic that forms the deck boards, as illustrated in Figure 18 for the intermediate plastic deck board 36.

The flame retardant material 120, 122 can be applied to the lower deck boards 50 (1) -50 (3) in the base layer 50, as well as the outer deck boards 32 and the intermediate deck boards 36 in the base layer. load 30. Alternatively, the flame retardant material 120, 122 can be applied to the deck boards in only one of the base and load layers 50, 30.

The flame retardant material 120, 122 may include flame retardant resins, fabrics and films, for example. The flame retardant material 120, 122 can be applied using a variety of suitable processes. For example, in mold processing, extrusion, coextrusion, lamination, and autoclaving are available techniques that are suitable for applying a flame retardant material to a plastic deck board. If the flame retardant material is in liquid form, it can be applied with a brush, roller or spray similar to the application of ordinary paint. The application of fire retardant material 120, 122 to the deck boards advantageously increases the fire resistance of the pallets 20 while reducing the safety risks associated with low fire resistance.

Many modifications and other embodiments of the invention will come to mind for one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and associated drawings. Therefore, it should be understood that the invention is not limited to the specific disclosed embodiments and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims (14)

1. A plastic pallet (20) comprising: a load-bearing layer (30) comprising a pair of horizontally positioned external plastic pallet boards (32) and at least one intermediate plastic pallet board (36) positioned horizontally between them, said at least one intermediate plastic pallet board (36) having horizontally positioned opposite side walls (37) and a plurality of spaced apart openings (38) extending at least partially through the opposite side walls, and said pair of outer plastic deck boards (32) having horizontally placed opposite inner and outer side walls (33 (1), 33 (2)), so that the outer side wall (33 (2)) is closed, and a plurality of separate openings (34) extending through the inner side wall (33 (1)) and not extending through the outer side wall (33 (2)) of each outer plastic deck board (32 ), the plurality of spaced openings (34) in the inner side wall (33 (1)) of each horizontally positioned outer plastic deck board (32) being aligned with the plurality of spaced openings (38) in a side wall ( 37) adjacent to said at least one horizontally positioned intermediate plastic deck board (36); a plurality of inserts (60) in the plurality of spaced openings (34, 38); a base layer (50) comprising a plurality of plastic deck boards (50 (1), 50 (2), 50 (3)) positioned horizontally orthogonal to said pair of external plastic deck boards (32) positioned horizontally already said at least one intermediate plastic pallet board (36) horizontally placed on said load layer (30); and a plurality of separate support structures (40) coupled between said base and load layers (30, 50) and forming spaces between them to receive a lifting member. The plastic pallet according to claim 1 further comprising a plurality of fasteners (70) that couple said base and load layers (30, 50) to said plurality of separate support structures (40). The plastic pallet according to claim 1, wherein at least one of the outer plastic pallet boards (32) and the at least one intermediate plastic pallet board (36) in the load layer ( 30) comprises a plastic / wood composite, and wherein at least one of the plastic deck boards (50 (1), 50 (2), 50 (3)) in the base layer (50) comprises a plastic / wood composite. 4. A method of making a pallet (20) comprising: forming a load-bearing layer (30) comprising a pair of horizontally positioned external plastic pallet boards (32) and at least one intermediate plastic pallet board (36) positioned horizontally between them, the at least one intermediate plastic deck board (36) having horizontally positioned opposite side walls (37) and a plurality of separate openings (38) extending at least partially through the opposite side walls, the pair of boards having external plastic pallet (32) horizontally positioned opposite internal and external side walls (33 (1), 33 (2)), so that the external side wall (33 (2)) is closed, and a plurality of separate openings (34) extending through the inner side wall (33 (1)) and not extending through the outer side wall (33 (2)) of each outer plastic deck board, and the plurality of spaced openings (34) in the inner side wall (33 (1)) of each horizontally placed outer plastic pallet board (32) are aligned with the plurality of spaced openings (38) in a side wall (37) adjacent to the at least one horizontally positioned intermediate plastic deck board (36); inserting a plurality of inserts (60) into the plurality of separate sets of openings (34, 38) for aligned inserts; forming a base layer (50) comprising a plurality of plastic deck boards (50 (1), 50 (2), 50 (3)) positioned horizontally orthogonal to the pair of external plastic deck boards (32) positioned horizontally and to the at least one intermediate plastic deck board (36) positioned horizontally on said loading layer (30); and coupling a plurality of spaced support structures (40) between said base and load layers (30, 50) and forming spaces between them to receive a lifting member. The method according to claim 4 or the plastic pallet according to claim 1, wherein each insert (60) is orthogonal to the pair of horizontally positioned external plastic pallet boards (32) and to the at least an intermediate plastic pallet board (36) positioned horizontally on said load layer (30). The method according to claim 4 or the plastic pallet according to claim 1, wherein the plurality of spaced apart openings (38) that extend at least partially through the opposite side walls (37) of The at least one horizontally positioned intermediate plastic pallet board (36) includes a first opening partially extending through one of the side walls and a second opening partially extending through the other side wall, with the openings first and second extending partially aligned and in contact with each other to form a continuous opening therethrough; and wherein the plurality of inserts (60) may comprise a single insert extending between the openings in the pair of horizontally positioned outer plastic deck boards (32) and through the continuous opening in the at least one deck board. intermediate plastic platform (36) placed horizontally. The method according to claim 4 or the plastic pallet according to claim 1, wherein the plurality of spaced openings (38) extending at least partially through the opposite side walls (37) of The at least one horizontally positioned intermediate plastic pallet board (36) includes a first opening partially extending through one of the side walls and a second opening partially extending through the other side wall, with the openings first and second extending partially aligned but not in contact with each other; and wherein the plurality of inserts (60) comprise separate inserts that extend between the openings in the pair of horizontally positioned outer plastic deck boards (32) and the first and second openings that partially extend into the at least one intermediate plastic platform board (36) positioned horizontally. The method according to claim 4 or the plastic pallet according to claim 1, wherein the plurality of separate openings (38) extending at least partially through the opposite side walls (37) of The at least one horizontally positioned intermediate plastic pallet board (36) includes a first opening partially extending through one of the side walls and a second opening partially extending through the other side wall, with the openings first and second that extend partially out of alignment and that do not extend through the opposite side wall; and wherein the plurality of inserts (60) comprise separate inserts that extend between the openings in the pair of horizontally positioned outer plastic deck boards (32) and the first and second openings that partially extend into the at least one intermediate plastic platform board (36) positioned horizontally. The method according to claim 4 or the plastic pallet according to claim 1, wherein each insert (60) comprises a tube. The method according to claim 4 or the plastic pallet according to claim 1, wherein the pair of horizontally positioned external plastic pallet boards (32) and the at least one intermediate plastic pallet board (36) horizontally placed has a height of H, and wherein an outer diameter of each insert (60) is within a range of 0.25H and 0.75H. The method according to claim 10 or the plastic pallet according to claim 1, wherein H equals 2.54 cm (1 inch), and wherein the outer diameter of each insert (60 ) is within a range of 0.635 and 1.905 cm (0.25 and 0.75 inches). The method according to claim 4 or the plastic pallet according to claim 1 wherein each insert (60) overlaps a respective horizontally positioned plastic pallet board on the base layer (50). The method according to claim 4 or the plastic pallet according to claim 1, wherein each support structure (40) is C-shaped. The method according to claim 4 or the plastic pallet according to claim 1, wherein at least one of the outer plastic pallet boards (32) and the at least one intermediate plastic pallet board (36) in the loading layer (30) comprises a flame retardant material, and in which at least one of the plastic deck boards (50 (1), 50 (2), 50 (3)) in the layer of base (50) comprises a flame retardant compound.