Claims
- 1. A method of manufacture of a metal pallet comprising a deck member having a planar upper surface formed by the intersection of a plural number of rod members with a plural number of flat bar members, the flat bar members each having an elongated thin edge and positioned such that the elongated thin edge is the top surface of the flat bar members, where the rod members are embedded within the flat bar members such that the upper surface of the rod members are flush with the top surface of each of the elongated thin edges of the flat bar members in order to define the planar upper surface of the deck member, the method comprising the steps of:providing a pressure resistance welding apparatus comprising a platen to apply pressure and a base to support a plural number of said flat bar members; placing said flat bar members onto said base; placing one or more said rod members across said top surface of each of said flat bar members; attaching electrical leads to said flat bar members adjacent the intersections of said one or more rod members and said flat bar members; applying current to said flat bar members in sufficient amount to cause melting of said flat bar members at said intersections; moving said platen to apply pressure to said one or more rod members to force said rod members into the melted intersections of said flat bar members until said upper surface of said one or more rod members is flush with said top surface of each of said flat bar members.
- 2. The method of claim 1, where said flat bar members are placed in a parallel manner.
- 3. The method of claim 2, where said one or more rod members are placed perpendicular to said flat bar members.
- 4. The method of claim 1, where said one or more rod members are plural in number and are placed in a parallel manner.
- 5. The method of claim 1, further comprising the steps of providing framing edge members and placing said framing edge members to the outside of said flat bar members, such that said one or more rod members also contact said framing edge members.
- 6. The method of claim 5, further comprising the steps of providing an outer frame member and connecting said outer frame member to said framing edge member.
- 7. The method of claim 6, further comprising the steps of providing skid members and connecting said skid members to said outer frame member.
- 8. The method of claim 7, further comprising the steps of providing skid uprights, interior upright members and bridging members, connecting said bridging members to said interior upright members, connecting said skid uprights to said skid members and said outer frame member, and connecting said interior upright members and said bridging members to said skid members and to some of said flat bar members.
- 9. The method of claim 5, where said framing edge members are longer than said flat bar members, and further comprising the steps of bending and connecting said framing edge members to said flat bar members.
- 10. A method of forming a metal pallet comprising a deck member having a planar upper surface formed by the intersection of a plural number of rod members with a plural number of flat bar members, the flat bar members each having a top surface and an elongated thin edge and positioned such that the elongated thin edge defines the top surface of the flat bar members, where the rod members each have an upper surface and are embedded within the flat bar members such that the upper surface of the rod members are flush with the top surface of each of the elongated thin edges of the flat bar members in order to define the planar upper surface of the deck member,the method comprising the steps of arranging said flat bar members such that said elongated thin edges are the top surface, laying said rod members across said top surfaces in intersecting manner, attaching electrical leads to said flat bar members beneath the intersecting junctions of said rod members, and applying pressure against said rod members while simultaneously applying current through said electrical leads to melt the top surface of said flat bar members in order to press said rod members into said flat bar members to create a planar upper surface deck member.
- 11. The method of claim 10, further comprising the step of creating a framing edge member around said flat bar members.
- 12. The method of claim 11, further comprising attaching an outer frame member to said framing edge member, and attaching support means to said deck member.
Parent Case Info
This application is a continuation-in-part of U.S. application Ser. No. 09/281,516, filed Mar. 30, 1999, now U.S. Pat. No. 6,095,292.
US Referenced Citations (5)
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
09/281516 |
Mar 1999 |
US |
Child |
09/577727 |
|
US |