BACKGROUND

Plastic pallets are customarily used to transport and store goods. A plastic pallet typically includes an upper deck and a lower deck separated by support blocks. The support blocks define a gap or opening between the upper and lower decks for receiving the tines from a forklift or pallet jack for moving the pallet.

In terms of durability, plastic pallets are susceptible to damage from impacts with the sharp metal tines of the forklift or pallet jack. In addition, if the tines are inserted too far between the upper and lower decks such that the wheels of the forklift or pallet jack are resting on the lower deck, then the upper deck becomes separated from the lower deck when the tines are lifted.

Depending on the extent of the damage to the plastic pallet, it may be repaired at a cost far less than replacing the entire plastic pallet. There are many types of repairable plastic pallets, as disclosed in U.S. Pat. Nos. 4,843,976; 5,413,052; and 5,791,261, for example. Even in view of these repairable plastic pallets, there is still a demand to increase durability, strength and reparability of plastic pallets.

SUMMARY

A pallet includes a top deck, a bottom deck, and a plurality of spaced apart support blocks coupled between the top and bottom decks and forming an opening therebetween for receiving a lifting member. The top deck has spaced apart upper and lower surfaces, with the lower surface having a plurality of top deck tab openings.

Each support block includes an inner wall having a rectangular shape surrounding an interior opening, and an outer wall having a rectangular shape surrounding the inner wall. The outer wall has an upper surface coplanar with an upper surface of the inner wall, and a lower surface coplanar with a lower surface of the inner wall. A plurality of ribs extend between the inner and outer walls and has an upper surface coplanar with an upper surface of the inner and outer walls, and a lower surface coplanar with a lower surface of the inner and outer walls.

A first plurality of upper tabs extend outwards from the upper surfaces of the inner wall and the plurality of ribs, with each tab comprising an angled contact surface for engaging the top deck tab openings. A second plurality of upper tabs extend outwards from the upper surfaces of the inner wall and the plurality of ribs, with each tab comprising an angled contact surface for engaging the top deck tab openings. The angled contact surfaces of the first and second plurality of upper tabs face away from each other.

Each top deck opening includes a flange, and each upper tab comprises a shoulder opposite the angled contact surface for engaging the flange in a respective top deck tab opening. The angled contact surface of each upper tab is configured to flexibly contact the flange in the respective top deck tab opening before the shoulder engages the flange when the top deck is coupled to the plurality of support blocks.

The first plurality of upper tabs are aligned with the second plurality of upper tabs. Each support block comprises a pair of spaced apart cap surfaces carried by the upper surface of the inner wall to cover a portion of the interior opening.

The bottom deck has spaced apart upper and lower surfaces, with the upper surface having a plurality of bottom deck tab openings. Each support block further includes first and second plurality of lower tabs. The first plurality of lower tabs extend outwards from the lower surfaces of the inner wall and the plurality of ribs, with each lower tab comprising an angled contact surface for engaging the bottom deck tab openings. The second plurality of lower tabs extend outwards from the lower surfaces of the inner wall and the plurality of ribs, with each lower tab comprising an angled contact surface for engaging the bottom deck tab openings. The angled contact surfaces of the first and second plurality of lower tabs face towards each other.

The first plurality of lower tabs are aligned with the second plurality of lower tabs. Each bottom deck opening includes a flange, and wherein each lower tab comprises a shoulder opposite the angled contact surface for engaging the flange in a respective bottom deck tab opening.

The bottom deck has spaced apart upper and lower surfaces, with the upper surface having a plurality of bottom deck tab openings. Each support block further includes first and second plurality of additional lower tabs. The first plurality of additional lower tabs extend outwards from the lower surfaces of the plurality of ribs, with each additional lower tab comprising an angled contact surface for engaging the bottom deck tab openings. The second plurality of additional lower tabs extend outwards from the lower surfaces of the plurality of ribs, with each additional lower tab comprising an angled contact surface for engaging the bottom deck tab openings. The angled contact surfaces of the first and second plurality of additional lower tabs face towards each other.

The top deck, the bottom deck and each support block comprises plastic.

Another aspect is directed to a method for making a pallet comprising forming a top deck, forming a bottom deck, and coupling a plurality of spaced apart support blocks between the top and bottom decks and forming an opening therebetween for receiving a lifting member. The top deck has spaced apart upper and lower surfaces, with the lower surface having a plurality of top deck tab openings.

Each support block includes an inner wall and an outer wall. The inner wall has a rectangular shape surrounding an interior opening. The outer wall has a rectangular shape surrounding the inner wall and has an upper surface coplanar with an upper surface of the inner wall, and a lower surface coplanar with a lower surface of the inner wall. A plurality of ribs extend between the inner and outer walls and has an upper surface coplanar with an upper surface of the inner and outer walls, and a lower surface coplanar with a lower surface of the inner and outer walls.

A first plurality of upper tabs extend outwards from the upper surfaces of the inner wall and the plurality of ribs, with each upper tab comprising an angled contact surface for engaging the top deck tab openings. A second plurality of upper tabs extend outwards from the upper surfaces of the inner wall and the plurality of ribs, with each upper tab comprising an angled contact surface for engaging the top deck tab openings. The angled contact surfaces of the first and second plurality of upper tabs face away from each other.

