Patent Publication Number: US-2003233963-A1

Title: Central pallet connector or post for use with grabber arms of a forklift

Description:
RELATED APPLICATIONS  
     [0001] The present Application claims the benefit of U.S. Provisional Patent Application No. 60/382,007, filed on May 17, 2002. 
    
    
     
       TECHNICAL FIELD  
       [0002] The present invention is generally directed to a central pallet connector or post, positioned midway between two corner pallet connectors or posts along an edge of a plastic pallet, for connecting a top deck and a bottom deck or base of the pallet; and more particular, to a molded bolt-less central pallet connector or post configured to be gripped by the grabber arms of a forklift and also to an integrally formed central pallet connector or post similarly configured to be gripped by the grabber arms.  
       BACKGROUND OF THE INVENTION  
       [0003] A plastic pallet assembly is typically constructed to provide a top deck and a bottom deck, joined together by a plurality of connectors or columns. The connectors are typically located at the corners of the pallet, and for larger pallets, between the corners along the periphery of the pallet assembly (i.e., center connectors), and in the interior of the pallet assembly.  
       [0004] Plastic pallet assemblies are increasingly used to store and transport items instead of wood pallet assemblies. Such wood pallet assemblies were typical constructed as a top series of boards connected to two to three two-by-four wood beams, and a bottom series of boards connected to the wood beams.  
       [0005] Forklifts designed to transport items on wood pallet assemblies typically include two grabber arms positioned between the tines of the lift. The grabber arms were designed to grip the two-by-four wood beam centrally located in the pallet assembly between the tines. This would help stabilize the pallet assembly on the forklift, especially when a worker has to step onto the pallet to handle the products while it is high on the storage racks.  
       [0006] Conventional plastic pallet assemblies did not include connectors that were easily installed that were capable of being gripped by the grabber arms which are designed for wood pallets. Accordingly, such assemblies could not take advantage of the stabilizing influence of the grabber arms.  
       SUMMARY OF THE INVENTION  
       [0007] The present invention provides a center connector or post for connecting a top deck and a bottom deck of a pallet assembly, especially a plastic pallet assembly. The connector is sized to allow a first grabber arm and a second grabber arm positioned between a first tine and a second tine of a forklift to engage and hold the pallet connector. The pallet connector has a first side, an opposing second side, a first end, an opposing second end, and a top surface and a bottom surface. A first top flange extends from the top surface of the connector for snap-fittingly connecting the pallet connector to a top deck of a pallet assembly; and, a first bottom flange extending from the bottom surface for snap-fittingly connecting the pallet connector to a bottom deck of a pallet assembly. More than one top or bottom flanges (hooks) can be used to secure the connector to the top deck or base.  
       [0008] The connector is preferably a one piece molded plastic having a plurality of ribs. The ribs may either extend outward from the sides of the connector, or upward and downward from the top or bottom of the connector.  
       [0009] The connector may further include a first brace member extending from the top surface and a second opposing brace member extending from the top surface spaced apart from the first brace member a sufficient distance to allow a first rib portion extending downwardly from a bottom surface of the top deck to fit between the first brace member and the second brace member. The first and second brace members are positioned proximate the first end of the pallet connector and the pallet connector further comprises a third brace member extending from the top surface proximate the second end of the pallet connector and an opposing fourth brace member extending from the top surface proximate the second end of the pallet connector spaced apart a sufficient distance from the third brace member to allow a second rib portion extending downwardly from the bottom surface of the top deck to fit between the third brace member and the fourth brace member. The bottom surface of the connector may also be provided with such braces.  
       [0010] The connector may further comprise a first platform portion extending from the first side proximate the bottom surface of the pallet connector, and a second platform portion extending from the second side proximate the bottom surface of the pallet connector.  
       [0011] The pallet connector preferably has a width from the first side to the second side of approximately two inches. Alternatively the width may be up to around five inches. The width will depend on the design of the grabber arms.  
       [0012] In an alternative embodiment, the invention is a pallet assembly comprising a top deck, a bottom deck, a pallet connector positioned at a perimeter of the pallet assembly midway between a first corner and a second corner, the pallet connector sized to allow a first grabber arm and a second grabber arm positioned between a first tine and a second tine of a forklift to engage and hold the pallet connector. The pallet connector has a first side, an opposing second side, a first end, an opposing second end, and having a top surface and a bottom surface, a first top flange extending from the top surface snap-fittingly connecting the pallet connector to the top deck of the pallet assembly and, a first bottom flange extending from the bottom surface snap-fittingly connecting the pallet connector to the bottom deck of the pallet assembly.  
       [0013] In yet another embodiment, the invention is a structure for connecting a top deck and bottom deck of a pallet assembly comprising a generally rectangular box shaped connector having a first side, an opposing second side, a first end and an opposing second end, a generally hollow interior portion having a plurality of internal ribs extending from an interior surface of the first side to an interior surface of the second side. The connector is sized to enable a first grabber arm and a second grabber arm positioned between a first tine and a second tine of a forklift mechanism to engage the connector and stabilize the pallet assembly. The connector may be removable, or alternatively, integrally formed as a cover post or column of one of the top deck or bottom deck.  
       [0014] Another aspect of the invention is a pallet assembly comprising a first plastic deck having a generally rectangular planar portion and an integrally formed connector extending outwardly proximate a perimeter of the first deck midway between a first corner and a second corner, the connector having a generally rectangular box shape having a first side, an opposing second side, a first end and an opposing second end, a generally hollow interior portion having a plurality of internal ribs extending from an interior surface of the first side to an interior surface of the second side. The connector is sized to enable a first grabber arm and a second grabber arm positioned between a first tine and a second tine of a forklift mechanism to engage the connector and stabilize said pallet assembly. The assembly further includes a second plastic deck connected to the connector.  
       [0015] A further embodiment is a pallet assembly comprising a first plastic deck having a generally rectangular planar portion and an integrally formed first connector portion extending outwardly from said planar portion proximate a perimeter of said first deck midway between a first corner and a second corner, the first connector portion having a generally rectangular shape and, a second plastic deck connected to the first plastic deck. The second plastic deck having a generally rectangular planar portion and an integrally formed second connector portion extending outwardly from the second deck planar portion. The second connector portion has a generally rectangular shape slightly larger than the rectangular shape of said first connector portion. The second connector portion positioned to surround the first connector portion, and is sized to enable a first grabber arm and a second grabber arm positioned between a first tine and a second tine of a forklift mechanism to engage the second connector portion and stabilize the pallet assembly.  
       [0016] In yet another embodiment, a pallet assembly having a center connector configured to allow gripping by grabber arms of a forklift comprises a first plastic deck having an integrally formed center connector located proximate a periphery of the deck between a first corner and a second corner of the deck. The connector includes a first flange for snap-fittingly connecting the connector to a second deck. The connector has sidewalls forming an outer profile configured for gripping by grabber arms of a forklift.  
       [0017] Another embodiment of the invention is a plastic pallet assembly comprising a top deck having an integral downwardly projecting center post portion, and a bottom deck having an integral upwardly projecting post portion connected to the downwardly projecting post portion. The downwardly projecting center post portion and the upwardly projecting post portion form a center post of the pallet assembly. The center post is configured to enable grabber arms of a forklift to grip the center post.  
       [0018] Further aspects of the invention are disclosed in the detailed description of the preferred embodiment, the drawings and the claims. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0019]FIG. 1 is a perspective view of a forklift being inserted into a pallet assembly;  
     [0020]FIG. 2 is a partial perspective view of grabber arms of a forklift engaging a center connector piece;  
     [0021]FIG. 3 is a perspective view of center connector for a plastic pallet;  
     [0022]FIG. 4 is a top plan view of the connector of FIG. 3;  
     [0023]FIG. 5 is a cross-sectional view of the connector of FIG. 2 attached to a top and bottom deck of a pallet assembly;  
     [0024]FIG. 6 is a perspective view of another center connector between a partial view of a top deck and a bottom deck of a pallet assembly;  
     [0025]FIG. 7 is a perspective view of the connector of FIG. 6 without the top deck, bottom deck, and securing bolt;  
     [0026]FIG. 8 is a top plan view of the connector of FIG. 7 between the grabber arms of one type of a forklift;  
     [0027]FIG. 9 is a top plan view of the connector of FIG. 7 between the grabber arms of a second type of forklift;  
     [0028]FIG. 10 is a perspective view of center connector;  
     [0029]FIG. 11 is a top plan view of the connector of FIG. 10;  
     [0030]FIG. 12 is plan view of an end of the connector of FIG. 10;  
     [0031]FIG. 13 is plan view of a side of the connector of FIG. 10;  
     [0032]FIG. 14 is a cross-sectional view of the connector of FIG. 11 taken along the lines  14 - 14 ;  
     [0033]FIG. 15 is a perspective view of another center connector;  
     [0034]FIG. 16 is a top plan view of the connector of FIG. 15;  
     [0035]FIG. 17 is a side plan view of the connector of FIG. 15;  
     [0036]FIG. 18 is a top plan view of the connector of FIG. 15 between one type of grabber arms of a forklift;  
     [0037]FIG. 19 is a top plan view of the connector of FIG. 15 between another type of grabber arms of a forklift;  
     [0038]FIG. 20 is a top plan view of another center connector;  
     [0039]FIG. 21 is a perspective view of the connector of FIG. 20;  
     [0040]FIG. 22 is a side plan view of the connector of FIG. 21;  
     [0041]FIG. 23 is a top plan view of the connector of FIG. 20 between one type of grabber arms of a forklift;  
     [0042]FIG. 24 is a top plan view of the connector of FIG. 20 between another type of grabber arms of a forklift;  
     [0043]FIG. 25 is a top plan view of another center connector;  
     [0044]FIG. 26 is a perspective view of the connector of FIG. 25;  
     [0045]FIG. 27 is a side plan view of the connector of FIG. 26;  
     [0046]FIG. 28 is a top plan view of the connector of FIG. 25 between one type of grabber arms of a forklift;  
     [0047]FIG. 29 is a top plan view of the connector of FIG. 25 between another type of grabber arms of a forklift;  
     [0048]FIG. 30 is a perspective view of a center connector;  
     [0049]FIG. 31 is a plan view of an end of the center connector of FIG. 30;  
     [0050]FIG. 32 is a top plan view of the connector of FIG. 30;  
     [0051]FIG. 33 is a bottom plan view of the connector of FIG. 30;  
     [0052]FIG. 34 is a side plan view of the connector of FIG. 30;  
     [0053]FIG. 35 is a perspective view of the connector of FIG. 30 connected to a bottom deck of a pallet assembly;  
     [0054]FIG. 36 is a perspective side view of the connector of FIG. 30 connected to the bottom deck and top deck of a pallet assembly;  
     [0055]FIG. 37 is a top plan view of the grabber arms of a on type of forklift;  
     [0056]FIG. 38 is a top plan view of the grabber arms of another type of forklift;  
     [0057]FIG. 39 is a top plan view of the grabber arms of another type of forklift;  
     [0058]FIG. 40 is a perspective view of a center connector in a pallet assembly;  
     [0059]FIG. 41 is a partial perspective view of the connector of FIG. 40 without the top deck of the pallet assembly;  
     [0060]FIG. 42 is a partial perspective view of a portion of a center connector attached to a top deck of a pallet assembly;  
     [0061]FIG. 43 is a partial perspective view of a portion of a center connector attached to a bottom deck of a pallet assembly;  
     [0062]FIG. 44 is a perspective view of a center connector having a first portion integral with a top deck and a second portion integral with a bottom deck of a pallet assembly;  
     [0063]FIG. 45 is an exploded perspective view of the assembly of FIG. 44;  
     [0064]FIG. 46 is a top plan view of another connector;  
     [0065]FIG. 47 is partial perspective view of a center connector between a top deck and a bottom deck of a pallet assembly;  
     [0066]FIG. 48 is a partial perspective partially exploded view of the pallet assembly of FIG. 47;  
     [0067]FIG. 49 is a perspective view of the connector of FIG. 48 only connected to a bottom deck;  
     [0068]FIG. 50 is another perspective view of the connector and bottom deck of FIG. 49;  
     [0069]FIG. 51 is a partial perspective view of the top deck of FIG. 47;  
     [0070]FIG. 52 is a partial perspective view of the top deck of FIG. 51 with the top surface of the top deck removed to show ribbing in the top deck;  
     [0071]FIG. 53 is a partial perspective view of the pallet assembly of FIG. 47 with the top surface of the top deck removed to show the engagement of the ribbing of the top deck with structure in the connector;  
     [0072]FIG. 54 is a partial perspective view of center connector with a top deck and a bottom deck of a pallet assembly;  
     [0073]FIG. 55 is a partial perspective partially exploded view of the pallet assembly of FIG. 54;  
     [0074]FIG. 56 is another partial perspective partially exploded view of the pallet assembly of FIG. 54;  
     [0075]FIG. 57 is a partial perspective view of the connector and top deck of the pallet assembly of FIG. 54;  
     [0076]FIG. 58 is a partial perspective view of the connector and the bottom deck of the pallet assembly of FIG. 54;  
     [0077]FIG. 59 is a partial perspective view of the connector and the bottom deck of the pallet assembly of FIG. 54 with the sleeve removed;  
     [0078]FIG. 60 is a perspective view of the sleeve shown in FIG. 54; and,  
     [0079] FIGS.  61 - 68  are various views of another center connector. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
     [0080] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.  
     [0081] A plastic pallet assembly  10  typically includes three major components: a generally rectangular or square bottom deck or base  12 ; a generally rectangular or square top deck  14 , and a plurality of columns or connectors  16  connecting the bottom deck  12  to the top deck  14 . The connectors  16  are typically placed in the corners  18  of the assembly  10 . Additionally, for larger pallet assemblies, connectors  16  are placed along the perimeter of the assembly midway between the comers  18 , and sometimes in the interior of the assembly (i.e., the center of the pallet assembly). As shown in FIG. 1, the connectors  16  are spaced so as to allow the first and second tines  20 ,  22  of a forklift  24  to be inserted into channels created between the connectors  16  to allow the forklift  24  to lift the pallet assembly (and the contents placed on the assembly).  
     [0082] In addition to the first and second tines, certain forklifts also include first and a second grabber arms  26 ,  28  positioned between the first and second tines  20 ,  22 . The grabber arms are able to grip a two-by-four wood beam, and are particularly useful for preventing the pallet from slipping away, especially when a worker is standing on the top of the pallet to handle products high on a storage rack. Such pallets typically were constructed of a plurality of boards forming a top deck connected to a plurality of boards forming a bottom deck or base by three or more two-by-four beams. The grabber arms could engage and hold onto a center beam. This would stabilize and secure the pallet.  
     [0083] For plastic pallets, the central post or connector is conventionally designed with a wide body for strength and general purposes. For example, a typical 40″×48″ plastic pallet would have a central post or connector with a width of 6″ to 8″. Plastic pallets are usually made of commodity plastic material such as High Density Polyethylene and Polypropylene which are not as strong as higher grades of plastics. Plastic pallets also need to be constructed with generally uniform and thin walls. They normally can not have a thick wall like a two by four wood board because: (1) a thick wall will greatly prolong the molding process hence the cost; and (2) a thick wall will have void and sink marks unless otherwise dealt with. The wall thickness on a conventional plastic pallet is usually between ⅛″ to ⅜″. Challenges therefore exist for a center post, most likely a narrow one such as less than 2″, being a part of a plastic pallet, made of plastic with fairly uniform and thin walls, being strong enough to endure the tough grabbing and twisting of the metal grabber arms which often have teeth, withstanding concentrated load, yet economical enough so as not to increase the total cost of the plastic pallet significantly.  
     [0084] One economical way of making a plastic pallet with such a center post is to make the post being a removable part. Therefore, the post and the rest of the plastic pallet can be made with two different materials and different processes. Such removable posts or connectors on a plastic pallet are covered by patents by Pigott, et al., under U.S. Pat. No. 4,843,976, U.S. Pat. No. 5,197,395, U.S. Pat. No. 5,579,686, U.S. DES. Pat. No. 398,731; CANADA 1,330,958; AUSTRALIA 650,837, EPO 0,583,796, EPO 0,796,203 etc. Improvements are made in designing a center post or connector suitable for the grabber arms on the forklifts.  
     [0085] One attempt to take advantage of the use of the grabber arms for plastic pallets is shown in FIGS.  3 - 5 . These Figures disclose a solid plastic connector  30  having a generally rectangular block  32  positioned within a groove  34  of a platform piece  36 . The block  32  and platform piece  36  were secured to the top and bottom decks  14 ,  12  of a plastic pallet assembly by a metal bolt  38 . A hole  40  was provided in the block  32 , which matched a hole  42  in the platform piece  36  to accommodate the bolt  38 . The block  32  was sized to resemble a two-by-four wood beam and functioned in a similar manner to the wood beam to allow the grabber arms  26  and  28  to engage the connector  30  and assist in lifting and stabilizing the pallet assembly.  
     [0086] Another attempt of providing a center connector sized to allow the grabber arms to engage the connector is shown in FIGS.  6 - 29 . The connector  44  is also formed from a solid block of plastic. The connector  44  includes recesses  46  in the side wall to allow the grabber arms, or extensions from the grabber arms, to obtain a secure grip on the connector  44 . The connector also includes braces  48  extending upwardly from the top surface of the connector and downwardly from the bottom surface of the connector. The braces engage and hold onto rib portions in the top deck and bottom deck, respectively, to provide a more secure pallet assembly to inhibit twisting of the center post or connector  44  by the grabber arms with respect to the top deck and the bottom deck.  
     [0087] Both of these designs were formed from solid blocks of plastic machined to the appropriate dimensions. Additionally, both designs utilize bolts to secure the connectors to the top and bottom decks of a pallet assembly.  
     [0088] As shown in FIGS.  30 - 34  a further improved connector is in the form of a molded plastic connector  50 . The connector  50  includes a first side  52 , an opposing second side  54 , a first end  56  and an opposing second end  58 . The connector  50  further includes a top surface  60  and a bottom surface  61  (the bottom surface is shown in the bottom plan view of FIG. 33). The top surface  60  further includes an integrally formed, flexible first flange  62  having a hook  64  and an integrally formed, flexible second flange  66  having a hook  68  extending upwardly from the top surface  60 . The first and second flanges  62 ,  66  engage abutments in a top deck  78  of a plastic pallet assembly and are used to connect the connector  50  to a top deck. Similarly, the bottom surface includes an integrally formed, flexible first flange  70  having a hook  72 , and an integrally formed second flange  74  having a hook  76  extending downwardly from the bottom surface  61 . The first and second flanges  70 ,  74  extending from the bottom surface  61  engage abutments  79  in a bottom deck of a plastic pallet assembly and connect the connector  50  to the bottom deck  80 . A connector  50  connecting a top and bottom deck of a plastic pallet assembly is shown in FIG. 36. FIG. 35 shows the connection of the connector  50  to the bottom deck  80 . The abutment  79  in the bottom deck is similar to the abutment in the top deck (not shown).  
     [0089] The top surface  60  of the connector  50  further includes a first brace  82  extending upwardly from the top surface  60 , and an opposing second brace  82  also extending upwardly from the top surface  60 . The first and second braces are separated by a channel  86 , and are preferably positioned proximate the first end  56  of the connector  50 . The top surface also includes a third brace  88 , and an opposing fourth brace  90  separated by a channel  92 , extending proximate the second  58  of the connector  50 . The braces are designed to engage or surround rib portions on the lower surface of the top deck  78  to inhibit twisting of the center post or connector  50  by the grabber arms with respect to the top deck  78  and the bottom deck  80  of the pallet assembly. Similarly, the bottom surface  61  includes a first brace  94 , an opposing second brace  96  separated from the first brace  94  by a channel  98  extending downwardly from the bottom surface proximate the first end  56  of the connector  50 , and a third brace  100 , an opposing fourth brace  102  separated from the third brace  100  by a channel  104  extending downwardly from the bottom surface  61  proximate the second end  58  of the connector  50 . The braces extending from the lower surface  61  engage or surround portions of ribs extending upwardly from the top surface of the bottom deck  80 , and similarly help prevent twisting of the center connector  50 .  
     [0090] The connector  50  shown in FIGS.  30 - 36  includes strengthening ribs  106  extending outward from a central portion toward the first side  52  and the second side  54  of the connector  50 . Alternatively, the connector  50  can be molded top to bottom and have ribs extend up and down from a central portion.  
     [0091] The connector  50  also includes a first platform portion  106  generally extending outward from the first side  52  proximate the lower surface  61 , and a second platform portion  108  generally extending outward from the second side  54  proximate the lower surface  61 . The first and second platform portions are preferably in the shape of the outline of prior connectors (such as that shown in FIG. 11 of U.S. Pat. No. 5,579,686). The platform portions  106 ,  108  thus fit into abutments or other structure in the bottom deck designed to hold such prior connectors, and provide further support for the connector. The connector  50  of the present invention does not necessarily have to include the platform portions.  
     [0092] The connector  50  has a generally rectangular shape and is sized to enable the grabber arms of a forklift to engage and hold the connector  50 . Preferably the connector  50  has a width of approximately two inches (to resemble a two-by-four wood beam). However, the width can be modified to accommodate the space between the grabber arms of different designs.  
     [0093] Additionally, the connector can be provided with recesses in one or both of the first side  52  and the second side  54  to accommodate features on or extending from the grabber arms to facilitate a secure grip by such arms.  
     [0094] Specifically, FIGS.  37 - 39  disclose various grabber arm configurations and extensions. Referring to FIG. 38, a forklift  110  includes a first grabber arm  112  and an opposing second grabber arm  114  disposed between a first tine  116  and a second tine  118 . The first grabber arm includes a contacting member in the form of a projection or teeth  120  at a distal end of the arm  112 . Similarly, the second grabber arm  114  also includes a projection or teeth  122  at a distal end of the arm  114 . To accommodate this configuration, the connector  50  can be provided with recesses  126  on the first and second sides  52 ,  54  sized to accept and hold the projections  120 ,  122 . Preferably, each side  52 ,  54  of the connector  50  includes two such recesses so that it does not matter which end  52 ,  54  is placed proximate the perimeter of the assembly to allow for ease in installation.  
     [0095] Referring to FIG. 37, the forklift  110  includes a first grabber arm  120  having a half moon flange  124  extending from the side of the arm  112 . The half moon flange can be spring loaded and biased outwardly to place pressure on objects between the first and second grabber arms  112 ,  114 . The connector  60  can be provided with a recess sized to accept and hold the flange  24  to provide a more secure grip on the connector  50 .  
     [0096] Referring to FIG. 39, the forklift includes a first grabber arm  112  with a flange or cam  126 , and a second grabber arm  114  with a flange or cam  128 . Again, the connector  50  can be provided with appropriately sized recesses to provide for a more secure grip from the grabber arms.  
     [0097] The embodiment described in FIGS.  30 - 36  provides several advantages over the solid block plastic pallet center pallet connectors. By providing integral flange connection pieces, the connector  50  can be snap-fitted to the bottom and top decks. This allows for greater speed and flexibility in installation. Additionally, such connectors are less costly because no bolt is required (which also reduces the number of parts that must be kept tracked of) and less plastic is used in the molded pieces. It also facilitates recycling of the plastic pallets without metal parts involved. Moreover, molding is less costly than machining the plastic block connectors.  
     [0098] In another embodiment, another central connector  130  is shown in FIGS.  40 - 42 . The connector is a generally block shaped piece having a first side  132 , an opposing second side  134 , a first end  136 , and an opposing second end  132 . Again, the connector is sized to allow the grabber arms (and any extensions thereof) to grip and hold the connector  130  when utilized with a forklift lifting a pallet assembly including such connectors  130 .  
     [0099] Referring to FIG. 42, the connector  130  is shown as part of a top deck  78  of a pallet assembly. The connector is generally hollow and includes a plurality of supporting and strengthening ribs  140  extending from one side of the interior of the connector  130  to the other. Rectangular shaped compartments  142  are formed between the ribs  140 . The connector includes a scalloped outer surface  144  for obtaining a better grip on the connector  130  by the grabber arms.  
     [0100] A plurality of cross-ribbed supports  146  are shown as part of the bottom deck of a pallet assembly in FIG. 43. These supports  146  are positioned within the compartments  142  of the connector  130  as shown in FIG. 41, and provide additional support against the compressive forces of the grabber arms. By separating the center connector into two portions, an outside shell and an inside support, they can be molded with fairly uniform and thin walls, also with relatively larger spaces between the ribs which are better for molding purposes. Yet, after assembly, they form a very strong structure by inserting one into another so as to provide support to the side wall with reduced spaces. Bonding means such as adhesives, snap-fitting, bonding, fastening or welding can be used to join the two parts together.  
     [0101] The connector  130  and supports (if utilized)  146  can also be separately molded plastic pieces that are subsequently connected to the bottom and top decks of a pallet assembly by bonding means such as adhesives or welding. Additionally, the connector  130  can also include flanges extending from the top and bottom of the connector  130  for snap-fittingly connecting the connector to the decks. In another embodiment, a separate sleeve  148  can be placed around the outside of the connector  130  to provide additional wear resistance and support. The sleeve can be the same material as the base plastic pallet. However, the sleeve is preferably made from a different material that is tougher and more durable than the typical plastic pallet material, such as some of the engineering thermoplastic resins, rubber, or metal. The sleeve can be made with an extrusion process that is more economical than the molding processes used to create the top and bottom decks of the pallet assembly. A separate sleeve over an inner post is the second way of making the grab-on post with a different material and a different process than the pallet main body itself. Alternatively, the sleeve can be made in multiple pieces and served as side covers that join the center post. For instance, two separate covers can be snapped from the sides onto the center post which can be provided with recesses for the snap-on hooks. The benefit for this embodiment is that the covers can be replaced after wearing and tearing without dismantling the pallet or the center post. Other methods of bonding such as welding, fastening, adhesion and inserting can be used.  
     [0102] In another embodiment, the center grab-on post is designed for a welded plastic pallet in which the pallet has a deck made of two parts, an upper deck and a lower deck, and a base. All three parts are welded together at a common welding line. The central connector is in the form of an integrally formed post extending from one of the top deck or the bottom deck of the pallet assembly, and an integrally formed sleeve extending from the other deck. An integrally formed post can extend upward from a bottom deck of a pallet assembly. The post is welded to a portion of an upper deck. A plurality of ribs or cross-ribs can extend across the interior of the post to provide additional strength and support. The top deck can further include an integrally formed sleeve extending downward. The sleeve can be aligned with and positioned to cover the post. The sleeve can be sized to allow the grabber arms of a forklift to engage and hold the connector. The distal end (i.e., from the top deck) of the sleeve can be configured to fit into a well formed in the bottom deck.  
     [0103] Another embodiment of a center connector configured to be held by the grabber arms of a forklift is shown in FIGS.  47 - 53 . FIG. 47 shows the connector  170  between partial cut-outs of a top deck  78  and a bottom deck  80 . In this embodiment, the connector  170  is integrally formed (i.e., molded) with the bottom deck  80  and is preferably snap-fittingly secured to the top deck  78 . However, this arrangement may be reversed and the connector can be integrally formed with the top deck  78  and then snap-fittingly secured to the bottom deck.  
     [0104] The connector  170  includes a main body  172  configured in a generally rectangular block shape adapted to be held by the grabber arms of a forklift. As shown in FIG. 48, the top of the connector  170  includes a first and a second flange or hook  174  and  176  for snap-fittingly connecting the connector  170  to the top deck  78 . The flanges  174 ,  176  fit into slots  178 ,  180  in the top deck  78 . Each slot  178 ,  180  includes a seat  182 ,  184  (also shown in FIGS. 51 and 52) for engaging a projection  186 ,  188  on the flanges  174 ,  176 . A well  189 ,  191  is provided for each flange  174 ,  176  to allow for a mold piece to form the undercut portion of the projections  186 ,  188 .  
     [0105] The top of the connector  170  also includes a first and second brace  190 ,  192  positioned proximate a first end  194  of the connector  170 , and a third and fourth brace  196 ,  198  positioned proximate a second end  200  of the connector  170 . As shown in FIG. 53, the braces  190 ,  192 ,  196  and  198  fit between ribs  202  in the top deck  78  (the top surface of the top deck  78  is not shown in FIG. 53 for clarity). The ribs  202  hold the braces in place and inhibit twisting of the connector  170  especially the hooks  174 ,  176  which are the weakest links about the decks  78 ,  80 .  
     [0106] Similar to some of the other embodiments, the sides of the body  172  of the connector  170  may include recesses  204  to facilitate gripping of the connector  170  by the grabber arms or extensions from the grabber arms.  
     [0107] FIGS.  54 - 60  show another embodiment of a center connector  210  integrally formed with a bottom deck  80  of a pallet assembly (again, the structure can be reversed, and the connector be integrally formed on the top deck). The connector  210  includes an integrally formed body  212  (i.e., with the bottom deck  80 —best shown in FIG. 59) surrounded by a protective sleeve  214 . The protective sleeve  214  can be made of a tougher plastic than the typical plastic used to form the bottom deck  80  and connector body  212 , and is replaceable when damaged or worn from use. The sleeve  214  is preferably made by an extrusion process; however, it may also be made by injection molding.  
     [0108] The body  212  of the connector includes a first well  213  and a second well  215 , connected by a bridge segment  217 . The top of the body  212  includes a first, second, third and fourth flange or hook  214 ,  216 ,  218  and  220  integrally formed with the body  212 . The flanges include projections  230 ,  232 ,  234  and  236  which fit into slots  238 ,  240 ,  242  and  244  of the top deck  78 , and abut seats  248 ,  250 ,  252  and  254 . Unlike the prior embodiments, the projections of the flanges are directed toward the sides  222  and  224  of the connector rather than the ends  226  and  228 . This is because the shape of the body  212  and the placement wells  213  and  215  inhibit positioning the flanges in other positions.  
     [0109] As shown in FIG. 57, the top deck  78  includes ribbing  256  configured to enclose and hold onto the outer edge of the top portion of the body  212  of the connector  210 . The sleeve  214  is not shown in the view of FIG. 57 for clarity purposes only. The sleeve  214  should be formed to have a height which is slightly less than the height of the body  212  so the body  212  can be held and supported by the ribbing  256 . Alternatively, the sleeve  214  can be formed with the same height as the body  212 , and the ribbing  256  can be configured to enclose and hold onto the outer edge of the top portion of the sleeve  214 . In either case, the ribbing  256  inhibits twisting of the connector, especially the hooks, about the deck and the base of the pallet. The base of the pallet can also have a well for the sleeve to sit in. This provides additional support to the sleeve and the post against the twisting.  
     [0110] In an alternative design, the connectors  170  and  210  can be welded to the top deck rather than secured by the flanges.  
     [0111] In yet another embodiment shown in FIGS.  44 - 45 , the center post  280  is designed for a welded plastic pallet where the welding line is around the middle of the post. In this embodiment, a first half or portion  282  of the center post is formed as an integral part of the top deck  78 , and a second half or portion  282  of the center post is formed as an integral part of the base  80 . FIG. 44 shows a portion of the pallet with a center post  280  designed for engagement by the grabber arms. FIG. 45 shows an exploded view of the first and second halves  282 ,  284  of the center posts before welding. The end surfaces of the partial post are preferably mirror image to each other. They are preferably at the same planes as of the other posts so the welding plane is flat one. A hot plate welding can be used to weld the center and the other posts together. The pallet then becomes an integral part. Other bonding processes can be utilized to join the pallet parts together as well. The interior of each portion  282 ,  284  may include support ribbing  286  or other support structure. Additionally, as described above with other embodiments, the sides of the center post may include recesses  288  to facilitate gripping by the grabber arms. An optional sleeve can also be used as described above.  
     [0112] The grab-on center connector or post of the present invention can be a separately-made part or parts. These separate parts can be joined to the main body of the pallet assembly through reversible processes such as snapping, fastening or non-reversible processes such as adhesion or welding. Additionally, the grab-on center post can have a separate sleeve or one or multiple side covers which can be joined to the center post by reversible processes such as snapping, inserting, fastening or non-reversible processes such as adhesion or welding. Alternatively, the grab-on center post can have an outer portion and an inner portion that are inserted into each other. Further, the grab-on center post can be an integral part of the deck and/or the base.  
     [0113] While specific embodiments have been illustrated and described, numerous modifications are possible without departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.