Abstract:
An industrial platform, specifically, a pallet or a container, for storing and transporting articles with attached RFID tags includes an electronic communications device having components that are tracked to identify the location and status of the platform. The device also includes components to communicate with the RFID tags attached to the articles, as well as RF tags located within the distribution environment. A microprocessor with memory manages and stores the information obtained from the multiple tags and components. A portable wireless device transmits data within distributed wireless networks. A power supply provides for mobility and autonomous operation. The device is part of a condition responsive indicating system that tracks the platform and monitors its contents in real time.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a division of U.S. patent application Ser. No 11/102,221 filed on Apr. 8, 2005, which claims the benefit of U.S. patent application Ser. No. 09/770,097 filed on Jan. 24, 2001, now U.S. Pat. No. 6,943,678 issued Sep. 13, 2005, and U.S. Provisional application No. 60/177,383, filed on Jan. 24, 2000. The disclosures of the above applications are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     This invention generally relates to thermoformed apparatus and more particularly to a polymeric pallet or container having a communications device. 
     2. Description of the Prior Art 
     The 48 inch by 40 inch wood pallet is an integral part of North America&#39;s distribution system, and is involved in one way or another in the movement of a significant proportion of all goods bought and sold. According to Material Handling Engineering, (October 1999), page 16, the U.S. Forest Service estimates there are 1.9 billion wooden pallets in America. Approximately 400 million new pallets are needed each year. 175 million of these are pallets repaired for reuse by industry. Therefore, roughly 225 million new wooden pallets enter the supply chain each year. The standard 48 inch by 40 inch wood pallet makes up a significant proportion of the total number of wood pallets within the over-all distribution system. 
     U.S. Forest Service researchers also found that 225 million wooden pallets are sent to landfills each year. According to CHEP Equipment Pooling Systems, the largest third party pallet leasing company with 94 million wooden pallets, the average 48 inch by 40 inch wooden pallet weighs between 28 pounds and 65 pound at time of manufacture (dry). These traditional wooden pallets range from 48 pounds to 110 pounds in weight (wet) at time of recycling or disposal. Using these figures, approximately 17.8 billion pounds of wood is deposited in landfills each year. APA, the Engineered Wood Association, estimates that a standard 48 inch by 40 inch style lumber stringer pallet has a three year life. The three year cost for this style of wooden pallet is estimated to be $11.74. A three year life is based on 15-24 trips per year. Conventional wooden pallets have limited residual value at the end of their useful life cycle. 
     According to the Grocery Manufacturers of America (hereinafter “GMA”), the largest end-user of traditional 48 inch by 40 inch wooden pallets within the North American distribution system, the current wooden pallet exchange system costs the industry nearly $2 billion to operate in 1991. For example, the trucking industry is unable to optimize semi trailer loading or per-unit transportation costs because GMA style pallets are not capable of true four-way entry. Drivers are required to exchange loaded pallets for empty pallets after delivery, and because of manual pallet handling injuries, workers compensation claims are significant. Grocery distributors are unable to use automated material handling equipment efficiently because unacceptable wooden pallets must be removed from the pallet supply chain. Grocery manufacturers and shippers experience product damage because of design flaws in traditional wooden pallets. Furthermore, unit loading is not evenly distributed with stringer pallet designs, which results in product and packaging damaged in transport. Manufacturers must use stronger and costlier packaging because of wooden pallet problems. Wooden pallet sanitation and moisture absorption difficulties affect meat and other food processors. Moreover, general pallet deterioration, manifested by protruding nails and staples, splintered wood and missing stringers, results in significant inefficiencies within the over-all distribution system. 
     More and more companies are finding it preferable to employ third-party pallet management services to control the costs and logistics of using wooden pallets. For example, some fruit growers require pallets on a seasonal basis. Wooden pallets may therefore be rented for short or long terms from third parties. Third party service companies offer nationwide access to pools of wooden pallets, have responsibility for collecting and redeploying pallets where they are needed, and keep the pallet pool at a relatively high level of quality to move product through the distribution channel. The pallet tracking and retrieval systems deployed by the third party providers are more elaborate and efficient than other segments within the wooden pallet market. For example, bar code labels have been used to manage the efficiency of conventional pallet assets. A direct line of sight is, however, required by the scanner to read a bar card label. The performance of these systems has been generally unreliable and costly to implement within a wooden pallet environment. 
     Conventional Radio Frequency Identification (hereinafter “RFID”) systems have also been used but without success for a number of reasons. For instance, there are too many makes and models of 48 inch by 40 inch wooden pallet in the market. Also, a standard protocol has not been advanced. Furthermore, pallet handling procedures, material deterioration, product damage and repair practices require a more robust RFID tag technology than is currently available and wood is not a stable platform for the attachment of many types of RFID tags. Additionally, radio frequencies are absorbed by moisture in wood, which makes tag reads unreliable. Standard harsh operating conditions within the wooden pallet distribution system, such as thermal shock, sanitation, flexure, vibration, compressive forces, and fork impacts, can cause tag transponder coils to break and fail. 
     The velocity at which 48 inch by 40 inch wooden pallets travel through the distribution system is far less than optimum because a significant proportion of wooden pallets are not suitable for transporting goods, damage free. Although 175 million pallets are repaired each year, industry observers claim as many as 70% of all wooden pallets have deteriorated from their original specifications. Unacceptable wooden pallets have to be separated from acceptable wooden pallets, which is time consuming, injurious and wasteful. Accordingly, a far larger pool of wooden pallets is maintained in operation than would otherwise be required under optimum conditions. The traditional 48 inch by 40 inch wooden pallet is therefore tremendously inefficient, costing industry billions of dollars annually. Wooden pallets also have considerable negative societal and environmental impacts because the recourses used to purchase, repair and dispose wooden pallets could be more effectively deployed in other less costly product technology alternatives. 
     Accordingly, plastic pallets have been used to replace wood pallets with some degree of success over the past several years. Plastic pallets are known for their longevity and are generally more durable, lighter weight, compatible with automated material handling equipment, easily sanitized and 100 percent recyclable. Conventional plastic pallets, however, suffer from one significant disadvantage in that they cost considerably more than a comparable wooden pallet. Thermoplastic materials constitute a significant proportion of the total cost of a plastic pallet, and a given amount of relatively expensive plastic material is required to produce a pallet with a measure of load-bearing strength that is comparable to wooden pallets. 
     As another example, U.S. Pat. No. 5,986,569 which issued to Mish et al. proposes applying a pressure sensitive tape to the backside of a tag carrier and affixing the carrier to an object. Generally speaking, however, exterior attachment methodologies are not sufficiently robust and durable. Tags affixed to the exterior of the pallet can be damaged through wear and tear, sanitation, forklift impacts, and the like. Also, U.S. Pat. No. 5,936,527 which issued to Isaacman, et al., proposes a “cell” comprising a host transceiver and several local hard lined interrogators that detect local tags. In the Isaacman arrangement, several cells can be networked, which allows any tagged object to be identified from any PC within a multi-cell network. 
     It is significant that plastic pallet suppliers has been unable to physically identify, locate and track, in real time, comparatively expensive plastic pallets within networks of distribution. It is one thing to lose a low cost wooden pallet, but it is another to loose an expensive asset. Different technologies have been proposed to attempt tracking of pallet assets within the distribution system, but these proposals have been incomplete with respect to system architectures, protocols and plastic pallet design intent. Barcodes have been used, but these require a direct line of sight and have therefore been difficult to implement. RFID tags have been placed upon traditional molded pallets to locate and track their positions within the distribution system, but this type of pallet is so much more expensive than a comparable wooden pallet that the cost justification for implementation is not economical. 
     Moreover, it is known that conditions within the operating environment affect the performance of the RFID system. Several U.S. patents disclose protocols, circuitry architectures and other enabling methods for ensuring the interrogator properly communicates with one or more tags within an interrogation zone; these include: U.S. Pat. No. 5,229,648 which issued to Shindley et al.; U.S. Pat. No. 5,479,416 which issued to Snodgrass et al.; U.S. Pat. No. 5,539,775 which issued to Tuttle et al.; U.S. Pat. No. 5,583,819 which issued to Roesner et al.; U.S. Pat. No. 5,818,348 which issued to Walezak et al.; U.S. Pat. No. 5,822,714 which issued to Cato; U.S. Pat. No. 5,929,779 which issued to MacLellen et al.; U.S. Pat. No. 5,942,987 which issued to Heinrich et al.; U.S. Pat. No. 5,955,950 which issued to Gallagher et al.; U.S. Pat. No. 5,963,144 which issued to Kruest and U.S. Pat. No. 5,986,570 which issued to Black et al. Still other proposals are offered to overcome the antenna-to-antenna communication difficulties conventionally experienced by tag carriers, such as pallets, as they travel through interrogation fields or portals. The rapidly changing angular geometry of a tag passing through a field or portal results in a diminishing duration and strength of signal transmission, which can produce unreliable tag reading results. The following U.S. Patents Nos. propose solutions to this particular problem: U.S. Pat. No. 5,661,457 which issued to Ghaffari et al.; U.S. Pat. No. 5,708,423 which issued to Ghaffari et al.; U.S. Pat. No. 5,686,928 which issued to Pritchett et al.; U.S. Pat. No. 5,995,898 which issued to Tuttle; and U.S. Pat. No. 5,999,091 which issued to Wortham. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention there is provided an apparatus for manufacturing extruded plastic sheet having RF devices that includes a local computer linked to a network. A sheet extruder has a first PLC linked to the local computer. An RF device applicator is spaced apart from the extruder and has a second PLC linked to the local computer. The local computer communicates with the network and the second PLC causes the applicator to selectively fix the RF device upon the extruded plastic sheet. 
     Further in accordance with the present invention there is provided an apparatus for a fixing RF devices to extruded sheet used in the manufacture of thermoformed articles that includes an extruder for providing the sheet. A gantry is spaced apart from the extruder and includes an inventory of RF devices. A press moves the RF devices in a fixed position upon the sheet. A PLC is linked to a computer in the network for controlling the operation of the press. 
     Additionally the present invention is directed to an apparatus for fixing RF devices to extruded sheet that includes an extruder to produce the sheet with the RF devices positioned thereon. A frame is provided comprising a roll of film and a roller. The roller compresses the film onto the sheet with the RF devices affixed therebetween. 
     Further the present invention is directed to a method for communicating information associated with extruded sheet from a network to a machine that subsequently modifies the sheet and includes the steps of providing a first apparatus to extrude the sheet. A second apparatus is spaced apart from the first apparatus to affix a RF device to the sheet. A third apparatus is spaced from the second apparatus to at least receive information from the RF device on the sheet and the received information being used by a machine PLC to configure a processing characteristic of the machine for subsequently modifying the sheet. 
     Further the present invention is directed to a thermoforming apparatus that includes a computer linked to a network. A first read/write module is linked to the computer with a first read/write module reading data stored in a RF device affixed to an extruded sheet. A first PLC is connected to the computer to receive the RF device data from the first module and to configure an operational characteristic of the apparatus based upon the received data. A controllable oven heats the sheet. A controllable platen with a controllable mold is attached thereto to controllably form the heated sheet into an article. A second read/write module is linked to the computer for writing data to the RF device affixed to the article. The written data is subsequently used to identify the article within the network. 
     Further in accordance with the present invention there is provided a system that includes a manufacturing machine, a receiver, and an electrical control system connected to the machine and the receiver. An extruded sheet with at least one data storage device is affixed thereto with the sheet being manufactured by the machine into an article. The receiver operably interfaces with the data storage device to ascertain data previously stored on the device and the control system changing manufacturing characteristics of the machine based upon data received from the device. 
     Further the present invention is directed to a system that includes a manufacturing machine. An extruded sheet with at least one data storage device fixed thereto with the sheet is manufactured by the machine into an article. A transceiver is linked to a network and operable to send new data to the affixed data device after being manufactured by the machine. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view showing a preferred embodiment of a thermoformed pallet having a radio frequency device of the present invention. 
         FIG. 2  is a fragmentary perspective view showing a twin sheet variation of the present invention pallet. 
         FIG. 3  is a perspective and fragmentary view showing a second variation of the present invention pallet. 
         FIG. 4  is a perspective view showing the radio frequency device employed in the present invention pallet. 
         FIGS. 5-7  are diagrammatic views showing the manufacturing process employed with the present invention pallet. 
         FIG. 8  is diagrammatic perspective view showing the orientation of one radio frequency device arrangement incorporated into the present invention pallet. 
         FIG. 9  is a diagrammatic view showing the manufacturing process employed with the present invention pallet. 
         FIGS. 10-12  are cross sectional views showing various radio frequency device locations within the present invention pallet. 
         FIG. 13  is a diagrammatic view showing the interaction between an interrogator and the radio frequency device employed with the present invention pallet. 
         FIG. 14  is a top elevational view showing an exemplary radio frequency device orientation employed with the present invention pallet. 
         FIG. 15  is a diagrammatic view showing the interaction between the interrogator and radio frequency device employed with the present invention pallet. 
         FIG. 16  is an exploded perspective view showing an interrogator incorporated into an alternate embodiment of the present invention pallet. 
         FIG. 17  is a cross sectional view showing replacement of a battery for the alternate embodiment of the present invention pallet. 
         FIG. 18  is a flow chart showing another preferred embodiment of the present invention pallet. 
         FIG. 19  is a diagrammatic view showing another preferred embodiment manufacturing process employed with the present invention pallet. 
         FIG. 20  is a perspective view showing the present invention pallet of  FIG. 19 . 
         FIG. 21  is a fragmentary side elevation view showing the present invention pallet of  FIG. 20 . 
         FIG. 22  is a cross-sectional view of a preferred embodiment tank container of the present invention. 
         FIG. 23  is a diagrammatic view showing another preferred embodiment tank container of the present invention. 
         FIG. 24  is an exploded perspective view showing an alternate embodiment renewable power supply device employed in the present invention apparatus. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIGS. 1-3 , the preferred embodiments of a pallet apparatus  2  of the present invention employs a nesting pallet  4  and a communications device, such as a radio frequency identification device  16 . Nesting pallet  4  has downwardly extending pallet legs  6  which are receivable in pallet pockets  8  of an adjacent pallet to provide a nesting configuration for consolidated storage and transportation. Pallet  4  is made of a plurality of polymeric plastic sheets thermoformed into a single article. Pallet  4  includes a top plastic sheet  10  and a bottom plastic sheet  12 . This arrangement is referred to as a twin sheet construction. In one preferred embodiment, plastic sheet  14 , shown in  FIG. 3 , is sandwiched between sheets  10  and  12 , in what is referred to as a triple sheet construction. One advantage of a triple sheet construction is that the same load bearing strength of a twin sheet construction can be provided with a much lower measure of relatively expensive plastic in a triple sheet construction. Therefore, depending upon the criteria of the end-user, triple sheet constructions can be used to provide either a lower cost or a stronger pallet  4 . The present invention pallet  4  can be made in accordance with U.S. patent application Ser. No. 09/377,792, entitled “Triple Sheet Thermoforming Apparatus, Methods and Articles” which was filed on Aug. 20, 1999 by S. Muirhead; this is incorporated by reference herein. In summary, this method of triple sheet thermoforming provides the same measure of load bearing strength with 25 percent to 50 percent less plastic material than current state of the art twin sheet thermoformed pallets. However, twin sheet thermoformed pallets characterized by U.S. Pat. No. 4,428,306 to Dresen et al., U.S. Pat. No. 5,638,760 to Jordan et al., or U.S. Pat. No. 5,676,064 to Shuert, can be used to practice certain aspects of the invention; these patents are incorporated by reference herein. A triple sheet thermoformed pallet is preferred because it provides a higher measure of strength for the given measure of plastic used by a twin sheet pallet, and is therefore more economically fulfilling the need for a low cost alternative to wooden pallets. 
     The RFID system is minimally composed of three components including an interrogator (reader or exciter), tag devises  16 , and a host computer. The tag is alerted by a radio frequency wave transmitted by the interrogator to return a data message by arrangement. The information stored in memory is thus transmitted back to the interrogator. Information received by an interrogator is used by a host computer to provide a reliable and a secure architecture that meets predetermined performance requirements. In passive RFID systems, the RF field generates voltage that is rectified to power the tag. In active RFID systems, a battery is the source of a tag&#39;s power supply. Both passive and active RFID devises may be embedded within the structure of the preferred plastic pallet. 
     Radio frequency identification tags and interrogators can be made in accordance with the following U.S. Pat. No. 6,027,027 entitled “Luggage Tag Assembly” which issued to Smithgall on Feb. 22, 2000 and U.S. Pat. No. 6,013,949 entitled “Miniature Radio Frequency Transceiver” which issued to Tuttle on Jan. 11, 2000. Both of these patents are incorporated by reference herein. 
     RFID device  16  is encapsulated between the sheets forming pallet  4 . In general, thermoplastic resins are extruded through a machine that produces a selective sheet or web of heat deformable plastic. As the preformed sheet or web travels through the extruder, one or more surfaces of the sheet receives one or more RFID tags. This may be done automatically or manually such that the tag is located on the plastic according to predetermined criteria corresponding to a select molding position upon the thermoforming tooling. Sheet thus tagged moves through a thermoforming machine that molds said sheet into a finished pallet. The tag or tags are sandwiched between the sheets of plastic forming the pallet at predetermined locations. In this manner, the tag is embedded, isolated, protected and contained in a fluid tight plastic barrier that is resilient and long lasting and not externally, physically visible. In order to ensure the RFID device is not damaged in the thermoforming process of preference, a high temperature RFID devise methodology, such as that described in U.S. Pat. No. 5,973,599 which issued to Nicholson et al., may be used; this patent is also incorporated by reference herein. The location of the device within the pallet is selected for system requirements. A plurality of locations can be used by cross-referencing machine and extrusion direction dimension references upon the plastic sheet with their counter part locations upon the properly thermoformed article. Thus, through such registration techniques, a consistent location for positioning the tag upon the sheet relative to its selected location in the finished part can be repeated with a high degree of certainty. In more detail, molded-in structures of the plastic pallet may be adapted to further protect the RFID device from flexural and compressive forces that may other wise damage the device. 
     The RFID devise  16  is part of a system in which data about the pallet  2  is stored for retrieval according to system criteria. The advantage of encapsulating RFID devise  16  within the structure a pallet  4  is so that the devise  16  is protected from the harsh environment that pallet  4  must operate within. 
     There are a number of methods that can be used to insert a RFID devise  16  within thermoformed pallet  4 . In one embodiment, RFID devise  16  is a passive RFID tag  18 . An example of such a passive tag  18  is shown in  FIG. 4 . Tag  18  comprises an antenna coil  20 , modulation circuitry  22  and micro-memory chip or integrated circuit  24 . Tag  18  is ultra thin, and in the order of 1½ square inches. A plurality of tags  18  are normally placed upon a polymer tape substrate by the tag manufacturer and delivered on reels for integration into a manufacturing process. 
     A plastic sheet is heated to a deformable temperature before it is molded by differential vacuum pressure over a mold. Intervention is required to integrate the tag  18  into the present thermoforming process in order to minimize stretching and heat deformation of the PET substrate. As shown in  FIGS. 4-6 , the first means of intervention includes depositing the coil  20  and circuitry  22  (composed of printable conductive ink) and the memory chip  24  upon a flexible film substrate  26 . Substrate  26  is composed of a plastic material that has a high heat deflection capability of &gt;600° F., such as Rodgers Engineering&#39;s electrical grade HT 12-1024 resin. After the tag  18  components are deposited onto the substrate  26 , a film substrate  28  of substantially the same construction is laminated over substrate  26  with a suitable high temperature resistant adhesive  30  there between to provide a double layered substrate assembly  32 . A first pressure sensitive, double sided film  36   a  is then applied to substrate assembly  32  on the substrate side. Substrate assembly  32  is subsequently sliced or severed such that individual tags  18   a  are produced. The tags  18  are separately and possibly sequentially deposited onto a paper or plastic carrier  34  with a single sided, pressure sensitive adhesive film  36   b . Plastic carrier  34  is wound around a hub  38  to produce a reel  40  that comprises a plurality of tags  18  that adhered to the surface of a plastic sheet by way of first adhesive film  36   a.    
     This arrangement produces a tag construction that is resistant to deformation under the short-term and high heat environment of the thermoforming process. Substrate  32  of tag  18  will not significantly stretch as the attached sheet  62  is deformed over a three dimensional molding surface. Moments of shear at the location of the tag  18  will also be deflected through movement of the adhesive film  36   a . Adhesive  30  will deflect compression upon the memory chip by providing a compression buffer (thickness) equal to the elevation of the memory chip  24 . In this manner, the tag  18  is developed to sustain the rigors of thermoforming. 
     Another alternate variation of the communications device in the structure of the pallet provides a power supply, an antenna, a radio frequency transmitter, a radio frequency receiver, a digital signal processor, a pallet information memory chip set, a pallet identification reader card, and circuitry. The memory chip set controls the function of the communicator and the identification reader card identifies the communicator and pallet. The communications device will thereby remotely communicate with an external interrogator in a wireless manner, such as by cellular telephone types of transmissions. This is used to instruct the interrogator to then query tags on or in the pallet or container. The interrogator also includes a power supply, an antenna, a radio frequency transmitter, a radio frequency receiver, a data processing micro-controller and circuitry. 
     Referring to  FIG. 7 , an X-Y gantry  42  is positioned along the path traveled by the web  44  of plastic material produced by the sheet extrusion machine (not shown). Gantry  42  cooperates with a programmable logic controller (hereinafter “PLC”)  46  that is connected to a local area networked personal computer (hereinafter “LAN PC”)  48 . Gantry  42  comprises linear high-speed indexer  50  that travels horizontally back and forth according to instructions from PLC  46 . Indexer  50  further comprises a reel  40  (see FIG.  6 )-to-reel  52  winder apparatus  54  with a vertical press  56 . As the web  44  travels through the gantry  42 , indexer  50  travels to a pre-defined location  58 , the winder apparatus  54  meters the reel  40  forward, carrying tag  18  into vertical alignment with press  56 . Press  56  is instructed to travel vertically to stamp tag  18  onto the web  44 . Plastic web  44  travels the length of the extruder and is finally sheared into a standardized sheet dimension at the end of the line thereby defining sheet  62 . Subsequently, the sheet and tag  18  are transported to a thermoforming machine for processing. 
     Referring to  FIG. 8 , plastic web  44  is adapted in the machine and extrusion directions to produce a plastic sheet that is dimensioned to be thermoformed against four separate molding application surfaces  64   a ,  64   b ,  64   c  and  64   d , illustrated separately by dashed line areas. In this manner, four pallets  4  are produced simultaneously in the thermoforming operation. Multiple tags  18  are located on sheet  62 . On each of surfaces  64   a  and  64   b , there are three tags  18 . There are also two tags  18  on surfaces  64   c  and  64   d . Thus, batches of pallets  4  can be custom made for different end-uses. The PC  48  interfaces with PLC  46  to instruct indexer  50  to deposit tags  18  in a selective manner. In other embodiments of the present invention, there may be multiple gantries  42  or multiple indexers  50  on one gantry  42  for depositing a variety of RFID tags  18   a ,  18   b ,  18   c ,  18   d  and  18   e  upon sheet  62 . Alternatively, host computer  80  may interface with LAN PC instructing further systems (not shown) to apply a sequential array of tags  18   a ,  18   b ,  18   c ,  18   d  or  18   e  upon the carrier  34  (see  FIG. 6 ) producing reel  40 , in the corresponding order to their deposition upon the sheet  62 . 
     In the preferred order of arrangement shown in  FIG. 9 , sheet  62  is thermoformed against a female mold located upon the lower platen of the thermoforming machine. In this manner, when sheet  62  is thermoformed, tags  18  will be encapsulated when molded sheet  68  is selectively fused to sheet  62  in the thermoforming process. This creates a protective barrier around the each tag  18 . It should be appreciated, however, that other sheet forming sequences may be utilized in a variety of thermoforming techniques to accomplish the present method. 
     One of the tags  18 , in this example tag  18   a , interfaces with a Manufacturing Management System (hereinafter “MMS”) deployed throughout the overall manufacturing infrastructure. Sheets  62 ,  68  and  70  (in the triple sheet method) are conveyed to a thermoforming machine RF interrogator field  72 , where a RFID tag interrogator  74  identifies and reads data stored on tags  18   a . Tags  18   a  send preprogrammed data packages back to interrogator  74   a . Interrogator  74   a  interfaces with LAN PC  76  connected to thermoforming machine PLC  78  interfacing through LAN to MMS host computer  80 . PLC  78  instructs machine and ancillary equipment how to process the plastic sheets  62 ,  68  and/or  70 . PLC  76  next instructs tooling  77  how to process the plastic sheets  62 ,  68  and/or  70 . If MMS criteria are not met, the thermoforming process is disabled. If MMS criteria are met, tag  18   a  traverses an interrogator field  82  and tag  18   a  writes and locks final data into non-volatile tag  18   a  memory before the pallet  4  exits said field to enter the supply chain. Other tags  18   b ,  18   c ,  18   d  and  18   e  do not interface with interrogator fields  72  and  82 . 
     Referring now to  FIG. 10 , pallet  4  is adapted to enhance the ability of devices  16  to survive long term pallet handling wear and tear. In particular, the tines  82  of a forklift vehicle  131  are used to move pallets  4  throughout the distribution network. When tines  82  are introduced between pallet legs  6  in order to support the weight of the pallet  4  for transportation, several potentially damaging events may occur. For example, the tines  82  may impact the sidewalls  84  of the Pallet  4  or the legs  6 . Therefore, when systems (new and pre-existing) criteria necessitates a relatively close read range, and it is desirable to position the devices  16  in the area of a side wall  84  or the outside feet  86 , it would be advantageous to affix devices  16 , such as tags  18  on the lower sheet of plastic  12  away from potential areas of tine  82  impacts. Devices  16  can also be advantageously positioned on sheet  10  as may be preferred in the embodiment used, with several acceptable locations being shown. As tines  82  are introduced through pallet  4 , abrasion and shear may also occur along the path traveled by the tines  82 . Accordingly, locations containing devices  16  may be reinforced to absorb and protect a device chamber  88  within which the devices  16  reside. This is illustrated in  FIG. 11 . A variety of potential chamber designs are possible in both twin and triple sheet constructions. In twin sheet constructions, the preferred methodology is to encapsulate each device  16  between two sheets of plastic  10  and  12  in an arrangement that provides compressive, flexural, shear and anti-abrasion strength in a zone  90  contiguous to the chamber  88 . A vertical side wall  92  of sheet  12  circumventing chamber  88  may incorporate vertical details  94  and/or horizontal details  96 , improving the strengthening criteria. Chamber  88  is further strengthened by top sheet  10  being locally recessed or lowered in side-to-side elevation so as to position the chamber away from the load bearing surface of pallet  4  and in particular the edges of packaging and objects supported thereon. 
     In triple sheet constructions, other pallet strengthening techniques can be used to increase the survivability of devices  16  within chamber  88 . Sheets  62 ,  68  and  70  are formed to substantially position chamber  88  between the top load-bearing surface  98  and the bottom tine contacting surface  100  of pallet  4  so that the devices  16  are isolated from damaging events within the core of the pallet  4 . This arrangement is illustrated in  FIG. 12 . 
     As understood in reference to  FIG. 13 , devices  16 , and in particular tag  18   b , are transported through zone  102  proximate interrogator  104 . Interrogator  104  interfaces with a LAN PC  106  networked to a Warehouse Management System (hereinafter “WMS”). This creates an implementation criteria that is reliable and secure for data retrieval and storage occurring while the pallet  4  transits through zone  102 . When the read/write distance capability of the interrogator  104  is limited and necessitates a predetermined orientation of pallet  4 , some inconvenience may occur because the pallet  4  will have to be, rotated 180°. As this is impractical within a smooth flowing WMS, two means of interventions may be taken to prevent this undesired handling. A first means is to apply color-coded polymeric strip  110  upon the plastic sheet  70  (see  FIGS. 19 and 20 ) at the time of extrusion which corresponds to the location of the devices  16 . In this manner, the pallet may be oriented by visual design for expediency. This will be discussed in further detail hereinafter. 
     System interference may also occur if a nearby devises  16  travels outside the interrogation zone  102  but through the interrogator&#39;s signal pattern  112 . Similarly, as the pallet  4  is traveling through the WMS, devise  16  may excite other interrogators coming within reader range. These occurrences may lead to unreliable data. In order to minimize these and other potential problems, it is preferred to encapsulate devises  16  along a center axis  114  of pallet  4 . This is shown in  FIG. 14 . Axis  114  may progress from either the long or short side of a 48 inch by 40 inch pallet  4 . Devises  16  are positioned along an axis  114 , which resides in a zone  115  contiguous to the center leg  116  of the pallet  4 . In this manner, the tag  18  can be interrogated from either the right or left hand side of the pallet  4 . 
     Referring to  FIG. 15 , where a RFID system is being employed within a new setting, it is advantageous to position elements of a fixed field interrogator, such as a transit portal  117 , upon, below or well above the ground along the path transited by the pallet  4 . Accordingly, an over or an under bearing RF link is provided when pallet  4  travels through the interrogator field  102   b . This arrangement also ensures that spaced apart metal tines  82  do not deflect interrogator signals, thus causing unreliable reads. In the preferred embodiment, elements of the interrogator that are positioned for an over or under bearing read pattern include the interrogator antenna assembly  118  and transmitter and receiver modules  120  and  122 , respectively, and an interrogator data processing and control module  124 , which is proximate LAN PC  126 . With this arrangement, improved read capability is integral to criteria for implementation reliability and security. 
     It may also be understood in connection with  FIG. 15 , that PC  126  may communicate with read result display(s)  127   a  positioned proximate interrogation zone  102   b  in a fixed location visible to the operator controlling the movement of the pallet, or wirelessly to a display  127   b  on a console  129  of a motorized pallet transporting vehicle  131 . In this manner, the system is integrated to facilitate economical movement of pallets  4  through interrogation portal  117  and distribution network. 
     In the present invention, a pallet and corresponding load of tagged objects, or stack of pallets, is positioned within the interrogation zone by a manually operated motorized pallet transporting vehicle. The interrogation field detects the vehicle within the zone by a triggering devise. The interrogator communicates with the tags in the zone, and upon completion of this task, communicates with a visual message delivery devise that is operative to instruct the driver to exit the interrogation field or pass through the portal. An LED light or the equivalent can be positioned on the drive console of the vehicle to inform the driver to stop and proceed. A stop and go light arrangement can also be positioned within the field of view of the driver to achieve the desired communication. Alternatively, the host computer receiving pallet information can interface with pallet transporting vehicle by displaying on a console where the pallet is to be stored within the warehouse. 
     Reference should now be made of  FIG. 16 . Another feature of the present invention employs encapsulating interrogator communications device  130  between the sheets forming the pallet  4 . Interrogator  130  could be adapted through system architecture to take an inventory of the tags  18  or sub-set of tags  18  residing upon the pallet  4 . It should be appreciated that interrogator  130  is a substantially larger device  16   a  than tag  18 . It may therefore be impractical to encapsulate the interrogator  130  within the pallet  4  in the process manner outlined above. In order to insert the interrogator  130  within the pallet  4 , the following methodologies would be preferred. In a twin sheet pallet construction, interrogator  130  is delivered to a selected location by means of a shuttle type delivery system that is adapted to move from a position outside the form station where apparatus loads an interrogator from a supply, to a position inside the form station, where the apparatus unloads the interrogator; it then shuttles back to load another interrogator, in between the time the first sheet  10  is thermoformed and when it is sequentially fused to thermoformed second sheet  12 . The shuttle type delivery system could also be adapted to locate a plurality of devices  16   a , also including tags  18 , between the time the first sheet  10  is molded and the second sheet  12  is fused to the first sheet  10  in a twin sheet construction. A shuttle system of the type may alternately be substituted with a robotic arm. 
     It will also be appreciated that interrogator  130  will draw a considerable amount of power for operation. Interrogator  130  is therefore active, with power supplied from a battery  132 . From time to time, interrogator battery  132  may be replaced according to a maintenance schedule contained in data array of one of tags  18 , preferably tag  18   a . As was also the case with tags  18 , interrogator  130  will fail if delicate instruments  133 , memory and integrated circuit chips  133   a  or circuitry  135  printed on a circuit board  137  are damaged during the high temperature and compression events of the thermoforming process. Intervention is thus required to insert battery-powered devise(s)  16  between sheets of plastic. 
     Interrogator  130  is enclosed in a heat and compression resistant thermoplastic housing  134 . The housing base  134   b  has a flange and thread section  135 . Thread section  135  accepts a thermoplastic seal and threaded plate  136 . The plate  136  is removable to replace or recharge battery  132 . Tags  18  may also be embedded in pallet  4  inside housing  134 . Alternatively, tags  18  are manufactured or deposited upon circuit board  137  of interrogator  130 . As shown battery,  132  may be mounted to plate  136  adapted to reconnect the battery as the plate is threaded to a closed position. Spring terminals  138 , concentrically arranged about an axis corresponding to the rotational path of the terminals  139  on the affixed battery  132 , are developed to ensure robust connection and enduring power supply. An EMI shield  141  is provided to prevent tag reading interference; otherwise multiple pallets with goods on each pallet stored on warehouse racking may demand the use of a directional antenna  142 . Housing flange  135  is larger in diameter than the circuit board assembly. The circuit board assembly can be removed for maintenance, upgrading and recycling of the pallet  4 . It is preferred that the housing  134  is recyclable with pallet when emptied. Other arrangements enclosing the devises in protective housings to withstand the rigors of thermoforming are also practical. 
     In order for the pallet interrogator  130  to communicate with a LAN PC, a Wireless Wide Area Communication System  140  is added. System  140  can be a cellular communicator inter-operating in an open standard environment. In the event FCC&#39;s E-911 mandate precludes utilizing cellular communications in this application (i.e. GPS), an alternative technology that can be used is wireless PC communications. The circuitry of a RF based interface PC card for a mobile PC devise could be deposited upon circuit board  137 . A local area Ethernet communicator interfaces the PC card circuitry with a LAN PC, and through the LAN PC by the Internet to host computer(s)  80 . One or more circuit board antennas  142  may be slave to several communications devises, as is battery  132 . 
     In the triple sheet configuration of  FIG. 17 , housing  134  is contained in chamber  88  formed between plastic sheets  12  and  14 . After first sheet  12  is thermoformed, a shuttle type delivery system is used to deliver housing  134  to chamber  88  such that flange  135  is selectively positioned upon first sheet  12 . Concurrently, sheet  14  is thermoformed. The shuttle is extracted from the forming station, and interfacial fusion next occurs where sheets  12  and  14  are compressed together in the thermoforming operation. Housing  134  is enclosed between two sheets of plastic. Third sheet  10  is thermoformed over a third molding surface and subsequently brought into compressive contact with sheets  14  and  12 . It is not necessary that sheet  10  fuse under compression with sheet  14  at the location of interrogator chamber  88 . Before (die cut in mold) or after pallet  4  exits the thermoforming operation, an orifice on sheet  12 , adjacent threaded section  135 , is removed (by trimming) to later receive battery pack  132  affixed to plate  136 . Alternatively, it may be advantageous to place housing  134  into a chamber formed by sheets  14  and  10 . It may also be advantageous to chill the plate so that when the plate expands thermally, it produces a more robust closure. 
     The wireless interrogator is instructed to identify a plurality or sub-set of the RFID tags associated with articles supported upon the pallet. Thus, a pallet would be able to perform, for example, its own inventory check by arrangement. 
     The present invention is further advantageous over conventional systems, such as that disclosed in U.S. Pat. No. 5,936,527, since inserting a wireless active interrogator in a plastic pallet of the present invention allows transportability and can be instructed to perform an operation anywhere or at any selected time within the wireless network. Examples of such a wireless network includes digital telephony, satellite communications, wireless Internet, microwave, cellular transmission and the like. Among other alternative embodiments of this aspect, is an optional renewable power supply devise  351  (see  FIG. 16 ) that rectifies voltage generated by antenna coils into stored energy in a battery at the interrogator in the plastic pallet or container. This affects battery size, replacement schedules, and other problems associated with wireless active interrogators. This renewable device generates energy, which recharges the associated battery, spring or other power reservoir in response to external agitational movement of the pallet during transit. The internal mechanism for the renewable device can be made in accordance with U.S. Pat. No. 4,500,213 entitled “Ultra-flat Self Winding Watch” which issued to Grimm on Feb. 19, 1985, and is incorporated be reference herein. The internal circuitry is shown in  FIG. 24  wherein the capacitor acts as the power storage reservoir. Renewable device  351 , employs an oscillating weight  361 , rotor  370 , top generating coil block  365 , circuit block  367  with an integrated circuit  370 , bottom generating coil  369 , capacitor/condenser  371  and battery/power source  373 . Battery  373  is electrically connected to the communications device, which includes an active tag  375 , and interrogator  377  and a communicator  379 . 
     Moreover, the wireless active interrogators could also be positioned within a molded structure forming part of the plastic pallet. A battery supply information field could be part of the manufacturing memory tag or third party pallet management memory array as preventative maintenance schedule field. 
     Yet another advantage of the aspect of encapsulating a plurality of RFID devises within the structure of a thermoformed pallet is that the same pallet can be tracked through different networks that interface according to differing substantially proprietary protocols. There are several popular data encoding methods, at least three data modulation standards and a handful of proprietary anti-collision backscatter formats. It is unlikely that in the future, one devise will be able to interface will all deployed systems, because an open standard for interoperability has not overcome issues with respect to proprietary technologies. There is also a range of operating environments and computer operating system platforms to interface with. A combination of devises within one product that enables functionality at many locations with pre-existing system infrastructures will help propel the plastic pallet through the distribution system. Notwithstanding one tag devise with several proprietary circuits could be coupled with one or more memory chips, and one antenna coil. 
     According to yet another aspect of the invention, one or a plurality of RFID devises may be provided within a single plastic pallet. For example, one such tag may be dedicated to manufacturing, material and recycle information storage. One tag may be specifically adapted for pallet tracking within the distribution system. The pallet may also host a third RFID devise specified by third parties for specialized inventory tracking activities within closed-loop or associated distribution networks. A fourth tag may be developed to consolidate the data arrays of several tags transported upon the pallet for more efficient data compression and transfer. A fifth tag may be adapted for interfacing with the RFID systems deployed by the trucking industry. Accordingly, one or more RFID devises may be embedded within one pallet to facilitate one or more operations according to different implementation objectives that ultimately increase the efficiency of plastic pallets. 
     According to this additional preferred aspect of the present invention, one RFID devise maybe used during the manufacturing process. A relatively simple, programmable passive RFID device that provides a bi-directional interface for one-time programming and multiple readings of the memory is used. The tag on the plastic sheet is interrogated to instruct the PLC of the thermoforming machine how the sheet is to be processed. In one such example, even though the standard 48 inch by 40 inch wooden pallet is designed to carry 2,800 pounds, the GMA claims approximately 30% of the unit loads weigh less than 1,000 pounds, and 66% of unit loads weight less than 2,000 pounds. Accordingly, the preferred thermoforming method may be used to produce a select range of standard plastic pallets, that are produced using different plastic formulations and processing guidelines, to meet different distribution system needs. The machine PLC may then be instructed to communicate to the tooling to instruct the tooling how to process the successive sheets. The thermoforming machine, production tooling and sheet materials thus interface with each other to recognize, synchronize, authenticate, implement and record manufacturing results to a manufacturing biased host computer. The memory array of the proposed devise is limited to read-only data transmission and is disabled from accepting further programming or erasing instructions once the pallet is made but before the tagged pallet enters the pallet supply stream. The memory array of the manufacturing related RFID devise will contain information pertaining to manufacture date, serial number, load bearing capabilities, operating temperatures, material composition, repair instructions, expiration date, recycling requirements, ownership, ISO certificates and the like. The data contained in the array could be tailored toward the needs of a third party pallet rental/leasing company, which can schedule and perform RFID and pallet maintenance. 
     This embodiment is explained in more detail as follows, with reference to  FIG. 18 . An end user customer requests a custom made final product by communicating his specifications manually to a sales office or through a remote electrical communications interface, such as the Internet. The control system computer will use predetermined algorithms and look up tables to automatically determine the optimum manufacturing criteria for these customer specifications. The determined manufacturing criteria is subsequently communicated to the tag manufacturing plant&#39;s local host computer. 
     The tags are sequentially deposited upon a roll at which point the tags receive selective data information which is pre-programmed or stored in the memory of each tag. The pre-formed sheets, containing the RFID tag, are subsequently conveyed to the thermoforming plant or machinery for processing into end products, shown in the figure as product A and product B. 
     The RFID tag on the sheet traverse and travel through the interrogation filed prior to entry of the sheet into the thermoforming machine. Data previously stored and programmed into the RFID tag memory is thereby communicated to the thermoforming machine PLC attached to the interrogator. The PLC thereby analyses the received data and adjusts the manufacturing operation and machinery as predetermined for the specific data criteria analyzed. 
     For example, fire retardant fillers in the plastic sheet require a longer period of time for heating in the ovens. Thus, data regarding the presence of fire retardant materials, which has been previously programmed or stored in the RFID tag memory, instructs the PLC of its presence and the PLC then controls the machinery to provide increased heat in the ovens for the specific sheet about to enter the ovens. The next sheet to be processed many not have a fire retardant filler and thus the PLC will accordingly vary the machinery and processing operation to reduce the oven heat applied to that subsequent sheet to be processed. In another example, an end product may be desired to have a metal frame inserted for increased load bearing strength. When the interrogator receives this information from the RFID tag attached to a sheet to be processed, the PLC operating the processing machinery will then instruct an auxiliary input A machine to insert a metal frame between a pair of sheets being processed. This can be done by a robotic arm or through other automation. The process is completed according to the preprogrammed manufacturing instructions in the machinery PLC, as altered or varied by data stored in the RFID tag for each sheet being processed. After completion, the PLC communicates the record of completion to a network computer for billing purposes and other statistical process control information. 
     Still according to this aspect of the present invention, one or more RFID devises can be used to identify, locate and track a pallet within the distribution network throughout the pallet&#39;s life cycle. In the manner, computer based tools can be utilized to increase the velocity of the pallet through the system. In other words, the pallets are managed as an asset rather than an expense. The pallet is tracked using a more complex programmable RFID device that provides a variety of operating modes (single tag/multiple tag environments), including multiple write and read (EEPROM) capabilities. Tagged pallets traverse interrogation fields distributed throughout the distribution network to record the pallet&#39;s progress through the distribution system. The RFID devises include anti-collision modulation options to resolve backscatter when multiple tags are in the same interrogation fields. Automatic pallet material handling equipment is upgraded to accommodate readers and communicators. Supply chain management and control of the movement of pallets through the distribution system are facilitated with real-time data input from the integrated RFID system. Host, interrogator and tag interface according to various implementation criteria, such as last scan time &amp; date, movement order number field, “from” field, “to” field, shipper field, pallet rental release field, and pallet return instructions. RFID technology provides a two-way flow of information between the pallet and the system server to help propel the pallet through the distribution system. The RFID devise may also carry its own electronic manifest. A more efficient use of plastic pallets will reduce the total number of pallets required by the over all distribution system. 
     According to a further feature of the invention, each RFID devise that may be contained in the pallet may be developed to operate on different radio frequencies (13.56 megahertz to 2.45 gigahertz) in order to optimize system performance and minimize the cost of interrogators and tags. Each devise may use a different coding waveform algorithm to reduce data recovery errors, bandwidth problems, synchronization limitations and other system design and cost considerations. For example, the pallet manufacturer does not need interrogation systems interfacing with the tracking systems, and versa visa. Thus, a less elaborate and costly RFID system is needed by the thermoforming manufacturer to deploy RFID systems. Similar tag devise transmissions may be echeloned according to prescribed system criteria or other pallet management tools or model algorithms. 
     As Faraday&#39;s law and Lenz&#39;s law are well known, it is also understood that the parallel orientation, and distance between the reader and tag antenna coils in respect of each other are important for the successful operation of passive RFID devises in particular. Read range is lower in higher frequency passive RFID devises. Furthermore, it is understood that induction is maximized when the antenna coils are perpendicular to the direction of the radio frequency signal. Therefore, another feature of the present invention provides for encapsulation of RFID devises within the structure of the plastic pallet. In one embodiment, an interrogator is contained in a vertical freestanding structure off to the side of the path traveled by the RFID devise. Accordingly, the antenna coils located in the interrogator and pallet are vertically oriented in approximate parallel condition to facilitate a proper signal transmission. In another embodiment, an interrogator is placed upon or under ground along the path traveled by the pallet, or alternatively suspended from above. In such an arrangement, it is advantageous to orient the respective antenna coils substantially horizontal in an approximate parallel condition to facilitate induction. These later arrangements would be difficult to duplicate and implement with wooden pallets because water absorbed by the wood would impede or reflect the RF signal away from the tag antenna. 
     A further preferred method of attaching RFID tags to polymeric sheets is as follows, with reference to  FIG. 19 . A polyethylene or polypropylene sheet  501  is created by an extruder  503  and a pair of opposed rolls  505 . The continuously created sheet is then fed through an indexer  507  at which point RFID tags  509  are fed from tag rolls  511  which are deposited in a spaced fashion upon an upper surface of sheet  501 . A narrow roll of polyethylene or polypropylene film  513  is simultaneously unwound from a film roll  517  and then compressed by a spring biased application roller  519  upon sheet  501  and covering each tag  509 . The film is thermally bonded to sheet  501  by compression of heated spring biased application roller  519 . The continuous sheet  501  is subsequently sheared or cut into separate preformed sheets  521  by a shearing machine  523 . 
     It is alternately envisioned that the film is colored so that it can be used to indicate tag location inside of a pallet for correct orientation to provide accurate readings as previously disclosed. For example, a plurality of colored films may be applied to denote RFID tag implementation criteria. For example,  FIGS. 20 and 21  show a four-up sheet wherein one operation yields four formed parts; in other words, four pre-formed sheets, with respective RFID tags, are not severed until after thermoforming. Film  513  is shown in two distinct and parallel, elongated locations covering RFID tags  509  upon the four-up sheet  521 . Film  513  further protects the underlying tags  509  as the leading edge  531  of a subsequently severed sheet is angularly moved along a lower sheet  521  during stacking. 
     Another preferred embodiment application of the thermoforming and communications device technology is shown in  FIG. 22 . In this embodiment, a gasoline fuel tank  601 , such as those used with an automobile, motorcycle, all-terrain vehicle, airplane, boat or other motorized vehicle, is made using twin or triple sheet thermoforming. Tank  601  is made of three, three-dimensionally formed sheets of plastic,  603 ,  605  and  607 , respectively, which are all joined together during processing. A bottom hollow section  609  operably contains a liquid, such as gasoline fuel. A top hollow section  611  contains fuel filler, filter, and other standard devices  613  necessary for the operation of tank  601 . 
     A communications device  621  is attached to an inside surface of sheet  607  within top hollow section  611  prior to thermoforming, as was previously disclosed herein with the pallet manufacturing. As the fuel is removed for engine combustion, environmentally hazardous gases are left to fill the space unoccupied by the fuel. Top hollow section  611  acts as a reservoir that contains the harmful gases that would otherwise escape through the devices  613  into the environment. The devices  613  can also recirculate the gas back into the lower hollow sections  609 , in a conventional manner. An instrument section of communications device  621  is operable to inspect and monitor the barrier performance of top hollow section  611  to ensure compliance with governmental regulations. When the vehicle is inspected, the data generated and stored by the instrument of device  621  is then conveyed through radio frequency communications to an external monitoring device operated by the governmental regulating authority for inspection purposes. The instrument section of device  621  can be battery activated in an active manner to provide regular intervals of inspection, can be passive to receive power when externally interrogated, or can be triggered one time when a predetermined threshold is met. 
     A further preferred application of the present invention is shown in  FIG. 23 . A bulk container  701  operably carries a hazardous material therein. For example, a two-part polyurethane container system is made from three sheets  703 ,  705  and  707  which are thermoformed and joined as previously disclosed herein to provide container  701  with two reservoirs  709  and  711 . Flange plates  713  and  715 , having threads, are formed onto container  701  to receive metering pump elements (not shown). These flange plates are made in accordance with those disclosed for battery replacement in the pallets. Pockets or receptacles  717  are created between adjacent internal sheets  703  and  705  at an overlapping margin to receive RFID tag devices. The RFID tags perform a range of functions which include recording of chemical formulas of material contained within reservoirs  709  and  711 , storage of safety data for storing, clean up information, worker injury information (such as that traditionally contained on a material safety data sheet), temperatures, thermal shock, and for disposal instructions. This data can later be interrogated by and external interrogator or the like. 
     While the preferred embodiment of the thermoformed pallet having a radio frequency device has been disclosed, it should be appreciated that other variations may be employed. For example, with a shuttle type delivery system and methodology, the gantry and laminator apparatus are not required. There are several other methodologies that may be used to practice the useful purposes of embedding sophisticated communications and other technological devices within the structure of a plastic pallet  2 . Furthermore, analog or solid state circuitry can be employed instead of the microprocessors, integrated circuits and computers disclosed. There are a number of different reinforcing structures that can be molded into two or more sheets of plastic to reinforce the area around the devices  16 . It is not necessary to form a complete chamber in plastic, so long as device  16  remains in the areas developed to protect the device from thermoforming shock, and operating wear and tear. It is also understood that access to the devices may be from the top or bottom in the wide variety of pallets contemplated in the present methodology. Furthermore, the RFID tags can also be attached to other heat and pressure formable sheets, such as cardboard, fiberglass, or the like, prior to three dimensional forming of the sheets. Additionally, the RFID tags and other electrical communications devices can be employed to monitor food conditions within a food container. While various materials have been disclosed, it should be appreciated that other materials can be employed. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention.