U.S. patent application number 13/071792 was filed with the patent office on 2011-08-11 for pallet with composite components.
This patent application is currently assigned to FITZPATRICK TECHNOLOGIES, LLC. Invention is credited to Terry L. INGHAM.
Application Number | 20110192326 13/071792 |
Document ID | / |
Family ID | 46325334 |
Filed Date | 2011-08-11 |
United States Patent
Application |
20110192326 |
Kind Code |
A1 |
INGHAM; Terry L. |
August 11, 2011 |
PALLET WITH COMPOSITE COMPONENTS
Abstract
A pallet comprising a first deck, a second deck, and a plurality
of block members connecting the first and second decks together to
form a pallet. The block members include at least one recycled
thermoplastic component including at least about 20% by weight of a
recycled nylon carpet material.
Inventors: |
INGHAM; Terry L.; (Oxford,
MI) |
Assignee: |
FITZPATRICK TECHNOLOGIES,
LLC
Oxford
MI
|
Family ID: |
46325334 |
Appl. No.: |
13/071792 |
Filed: |
March 25, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12564443 |
Sep 22, 2009 |
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13071792 |
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11277560 |
Mar 27, 2006 |
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12564443 |
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11184709 |
Jul 19, 2005 |
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11277560 |
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Current U.S.
Class: |
108/57.17 ;
108/57.33 |
Current CPC
Class: |
B65D 2519/00273
20130101; B65D 2519/00034 20130101; B65D 2519/0086 20130101; B65D
2519/00109 20130101; B65D 2519/00069 20130101; B65D 2519/00323
20130101; B65D 2519/00293 20130101; B65D 2519/00333 20130101; B65D
2519/00378 20130101; B65D 19/0048 20130101 |
Class at
Publication: |
108/57.17 ;
108/57.33 |
International
Class: |
B65D 19/38 20060101
B65D019/38 |
Claims
1. A pallet comprising: a first deck; a second deck; and a
plurality of block members connecting the first and second decks
together to form a pallet, the block members including at least one
recycled thermoplastic component including at least about 20% by
weight of a recycled nylon carpet material.
2. The pallet according to claim 1, wherein the block members
further comprise natural material particles selected from the group
consisting of: Apache Plume; Ash, single-leaf; Bitterbrush;
Cliffrose; Fendlerbush; Juniper, one-seed; Juniper, rocky mountain;
Mahogany, curl-leaf; Mahogany, mountain; Mock Orange; Ponderosa
Pine; Mormon Tea; and mixtures thereof.
3. The pallet according to claim 1, wherein the block members
further comprise at least one recycled material selected from the
group consisting of polypropylene, polyethylene, polyurethane,
polyvinylchloride, poly(ethylene terephthalate), polystyrene,
polybutadiene, and mixtures thereof.
4. The pallet according to claim 1, wherein the block members
further comprise at least one recycled material selected from the
group consisting of bottling containers, automotive plastic
components, agricultural films, rubber tires, fabrics, textiles,
reclaimed paper, sanitary paper products, and mixtures thereof.
5. The pallet according to claim 1, wherein at least one of the
first and second decks comprises a substantially rectangular frame
having a plurality of longitudinally and laterally extending cross
members, further wherein at least one of the plurality of cross
members comprises a composite material including at least about 20%
by weight of recycled nylon material.
6. The pallet according to claim 5, wherein the at least one cross
member comprises a lead board.
7. The pallet according to claim 1, wherein the block members
comprise at least about 50% by weight of recycled nylon carpet
material.
8. The pallet according to claim 7, wherein the block members
comprise at least about 75% by weight of a recycled nylon carpet
material including a major portion of nylon 6 and/or nylon 6,6.
9. The pallet according to claim 1, wherein the block members
further comprise at least one filler selected from the group
consisting of colorants, UV protectors, flame and fire retardants,
lubricants, soaps, polymer initiators, coupling agents, foaming
agents, and mixtures thereof.
10. The pallet according to claim 1, wherein the block members are
formed using extrusion techniques.
11. A pallet comprising: a first deck comprising a first plurality
of cross members; a second deck comprising a second plurality of
cross members; and a plurality of block members connecting the
first and second decks together to form a pallet, wherein at least
one block member and at least one cross member of the first or
second plurality of cross members include at least one recycled
thermoplastic component including at least about 20% by weight of a
recycled nylon carpet material.
12. The pallet according to claim 11, wherein the at least one
cross member comprises a lead board.
13. The pallet according to claim 11, wherein the at least one
block member and at least one cross member further comprise at
least one recycled material selected from the group consisting of
polypropylene, polyethylene, polyurethane, polyvinylchloride,
poly(ethylene terephthalate), nylon, polystyrene, polybutadiene,
and mixtures thereof.
14. The pallet according to claim 11, wherein the at least one
block member and at least one cross member further comprise at
least one filler selected from the group consisting of colorants,
UV protectors, flame and fire retardants, lubricants, soaps,
polymer initiators, coupling agents, wood fibers, foaming agents,
and mixtures thereof.
15. The pallet according to claim 11, wherein the at least one
block member and at least one cross member further comprise at
least one recycled material selected from the group consisting of
bottling containers, automotive plastic components, agricultural
films, rubber tires, fabrics, textiles, reclaimed paper, sanitary
paper products, and mixtures thereof.
16. The pallet according to claim 11, wherein the at least one
block member and at least one cross member comprise at least about
75% by weight of a recycled nylon carpet material including a major
portion of nylon 6 and/or nylon 6,6.
17. A pallet comprising: at least one deck; and a plurality of
extruded block members fastened to the deck by screws or nails;
wherein the block members are formed using extrusion techniques
from a mixture comprising polypropylene and at least about 50% by
weight of a recycled carpet material containing tufts of nylon 6 or
nylon 6,6.
18. A pallet according to claim 17, wherein the mixture further
comprises at least one recycled material selected from the group
consisting of: bottling containers, automotive plastic components,
agricultural films, rubber tires, fabrics, textiles, reclaimed
paper, sanitary paper products, and mixtures thereof.
19. A pallet according to claim 17, wherein the mixture further
comprises natural material particles selected from the group
consisting of: Apache Plume; Ash, single-leaf; Bitterbrush;
Cliffrose; Fendlerbush; Juniper, one-seed; Juniper, rocky mountain;
Mahogany, curl-leaf; Mahogany, mountain; Mock Orange; Ponderosa
Pine; Mormon Tea; and mixtures thereof.
20. A pallet according to claim 17, wherein the mixture further
comprises ground natural particles selected from the group
consisting of: whole trees, root particles, trunk particles, branch
particles, needle particles, wood particles, and mixtures thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/564,443 filed on Sep. 22, 2009, which is a
continuation of U.S. patent application Ser. No. 11/277,560 filed
on Mar. 27, 2006, now abandoned, which is a continuation-in-part of
U.S. patent application Ser. No. 11/184,709 filed on Jul. 19, 2005,
now abandoned.
FIELD
[0002] The present disclosure relates to a pallet, and more
particularly, a pallet having recycled components.
BACKGROUND
[0003] The common wooden and plastic industrial pallets are
generally known in the art. Such pallets, however, have several
shortcomings in regards to cost, quality, limitations of their use,
and ease of manufacture. Wooden pallets are typically constructed
by sandwiching wooden block members between two similar decks or
surfaces. Since the aesthetic appearance of pallets may not
outweigh the cost, they may often include scrap or recycled wood.
The surfaces may be made of a continuous sheet or, more commonly,
have a plurality of wooden boards typically arranged in a parallel
manner. Generally, the surfaces and blocks are stacked or arranged
to provide apertures suitable for access by the tines of a forklift
truck or pallet jack from at least one side. In certain instances,
the tines of a fork-lift truck make contact with the block members
during alignment. If the force is significant, the block members
can be damaged.
[0004] By its nature, ordinary wood may be subject to swelling,
warping, shrinkage, splintering, deterioration and fungal or
bacterial growth after exposure to moisture and other elements.
Pallets assembled with inferior quality wood blocks and/or boards
may lead to potential cargo damage.
[0005] Attempts to overcome the drawbacks of ordinary wooden
pallets with plastic pallets have been faced with similar
shortcomings. Prior designs of plastic pallets have had to deal
with issues such as the trade off between cost and weight bearing
capability. Typically, plastic pallets designed with a significant
weight bearing capability have tended to be both heavy and
expensive. In the same manner, inexpensive plastic pallets have had
both strength and durability issues.
[0006] In recent times, society has expended significant efforts on
continuing the development of more environmentally-friendly methods
for reusing various synthetic and plastic materials. It is
therefore desirable to provide a long-life pallet at least
partially derived from recycled components and having outstanding
physical attributes that is relatively inexpensive and can be
manufactured with relative ease. Specifically, it is desirable to
provide a low cost pallet that meets and exceeds stringent strength
and design standards.
SUMMARY
[0007] The present disclosure provides a pallet comprising a first
deck, a second deck, and a plurality of block members connecting
the first and second decks together to form a pallet. The block
members include at least one recycled thermoplastic component
including at least about 20% by weight of a recycled nylon carpet
material.
[0008] The present disclosure also relates to a pallet including a
first deck comprising a first plurality of cross members, and a
second deck comprising a second plurality of cross members. A
plurality of block members connect the first and second decks
together to form the pallet. At least one block member and at least
one cross member of the first or second plurality of cross members
include at least one recycled thermoplastic component having at
least about 20% by weight of a recycled nylon carpet material.
[0009] In another embodiment, a pallet is provided comprising at
least one deck and a plurality of extruded block members fastened
to the deck by screws or nails. The block members are formed using
extrusion techniques from a mixture including polypropylene and at
least about 50% by weight of a recycled carpet material containing
tufts of nylon 6 or nylon 6,6.
[0010] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present disclosure will become more fully understood
from the detailed description and the accompanying drawings,
wherein:
[0012] FIG. 1 is a perspective view of a pallet in accordance with
teachings of the present disclosure;
[0013] FIG. 2 is an exploded perspective view of a pallet according
to the present disclosure and showing individual components
thereof;
[0014] FIG. 3 is a perspective view of a first block member
comprising recycled material according to the present
disclosure;
[0015] FIG. 4 is a top view of the block member of FIG. 3;
[0016] FIG. 5 is a side view of the block member of FIG. 3;
[0017] FIG. 6 is a perspective view of a second block member
according to the present disclosure;
[0018] FIG. 7 is a top view of the block member of FIG. 6;
[0019] FIG. 8 is a side view of the block member of FIG. 6;
[0020] FIG. 9 is a perspective view of a third block member
according to the present disclosure;
[0021] FIG. 10 is a side view of the block member of FIG. 9;
[0022] FIG. 11 is a top view of the block member of FIG. 9;
[0023] FIG. 12 is a perspective view of a fourth block member
according to the present disclosure;
[0024] FIG. 13 is a top view of the block member of FIG. 12;
[0025] FIG. 14 is a side view of the block member of FIG. 12;
and
[0026] FIG. 15 is a perspective view of a fifth block member
according to the present disclosure.
[0027] It should be noted that the figures set forth herein are
intended to exemplify the general characteristics of an apparatus,
materials, and methods among those of this disclosure, for the
purpose of the description of such embodiments herein. These
figures may not precisely reflect the characteristics of any given
embodiment, and are not necessarily intended to define or limit
specific embodiments within the scope of this disclosure.
DETAILED DESCRIPTION
[0028] The following description of the present disclosure is
merely exemplary in nature and is in no way intended to limit the
disclosure, its application, or uses. For purposes of clarity, it
should be understood that throughout the drawings, corresponding
reference numerals indicate like or corresponding parts and
features.
[0029] In various embodiments, the present disclosure provides a
pallet including a first deck, a second deck and a plurality of
block members connecting the first and second decks together. The
block members, and optionally certain boards or cross members of
the decks, may comprise a high strength composite material
including at least one recycled thermoplastic component, preferably
including at least 20% by weight of a recycled nylon carpet
material. The recycled nylon carpet material particles may be
present in an amount up to about 50% by weight, or up to about 75%
or even 90% by weight, including a major portion of nylon 6 and/or
nylon 6,6 depending on the specific design. In various embodiments,
such nylon material is provided in an amount from about 80% to
about 85% by weight. The composite material has excellent
resistance to chemicals, including strong solvents, and is not
moisture or odor absorbent. Such composite blocks and/or cross
member boards containing recycled materials according to the
present disclosure are robust and rugged in construction,
configured to withstand the weight of goods stacked on them and to
withstand the impact of truck forks driven into them as a result of
misalignment. A pallet comprising such composite material also has
the capability of being fitted with RFID technology.
[0030] Various conventional nylon based carpeting useful with the
present disclosure typically includes at least three primary
components, namely a plurality of tufts formed from nylon, at least
one backing typically formed from polyolefins such as
polypropylene, and an adhesive material applied as a latex and
typically filled with an organic filler such as calcium carbonate.
In various embodiments, the nylon tufts include a major portion of
nylon 6; nylon 6,6; or blends or copolymers thereof. While this
multi-component carpet product may present challenges to typical
recycling efforts due to the varying chemical and physical
characteristics of its individual components in different forms,
such nylon containing carpet, both new and used, is useful in the
preparation of a composite material for use in a pallet according
to the present disclosure. If desired, various methods are known in
the art useful for converting an "unseparated" carpet into a
thermoplastic material formed from a melt blend of the materials
which originally comprised the carpet. For example, U.S. Pat. No.
5,294,384 to David et al. which is incorporated herein by reference
in its entirety, discloses a process for forming a thermoplastic
composition from carpet wherein a carpet sample is melted and
blended without separating the carpet into its various parts.
[0031] The composite material may also include various plastic
materials in addition to that in the recycled nylon carpet. As used
herein, "plastic material" includes, but is not limited to, plastic
materials suitable for use in a high strength composite material
for a pallet, such as thermoplastic polymers resistant to many
chemical solvents, bases and acids, for example, polypropylene,
polyethylene, polyurethane, polyvinylchloride, and poly(ethylene
terephthalate). The plastic material may also include various types
and grades of nylon, such as nylon 6 and nylon 6, 6. Recycled nylon
can be obtained from many industrial type sources, for example from
automotive uses, such as nylon gears; rubber textiles; and rubber
fabrics. The plastic may be selected depending on the specific
pallet design, load capacity, and other requirements. In various
embodiments, the block members may be manufactured with either
recycled components alone or combination with at least one prime or
virgin material. Thus the composite material may include various
grades of virgin plastic, recycled plastic, and mixtures
thereof.
[0032] In various embodiments, the composite material of the
present disclosure comprises at least 20% by weight of recycled
nylon carpet material. In one embodiment, the composite material
includes a major portion of nylon 6 and nylon 6,6, for example up
to about 50% by weight, in some embodiments, up to about 80% by
weight. According to other embodiments detailed below, the
composite material may comprise greater than about 20% by weight of
natural material particles, or greater than about 50% by weight, or
even greater than 80% by weight. It should be understood that all
weight percentages described herein can be increased or decreased
between 0% and 100% for a desired composite material, depending on
the specific design and selection of materials, and these
variations are within the scope of the present disclosure.
[0033] In various embodiments, the composite material may further
include at least one ground recycled material selected from the
group consisting of bottling containers, automotive rubber and
plastic components, agricultural films, rubber and rubber tires,
fabrics, textiles, reclaimed paper, sanitary paper products, and
mixtures thereof. In various embodiments, the block members may be
manufactured with such recycled components alone or combination
with at least one prime or virgin material. In most instances, the
recycled materials are shredded prior to use, as opposed to being
in their original size and shape. Shredding would include any type
of cutting, grinding, chopping, or other reducing operation that
cuts or tears apart recyclable materials, or any portion thereof,
to create smaller pieces for use in the composite material of the
present disclosure.
[0034] As used herein, bottling containers may include typical
recycled fluorinated plastic containers or PET type containers
including, for example, those commonly used to store and/or
transport various liquids. Automotive rubber and plastic components
may include any and all suitable recyclable materials derived from
automobiles and/or automotive equipment. Rubber includes industrial
rubber compounds, such as those typically derived from polystyrene,
polybutadiene, and poly(styrene-butadiene-styrene) or SBS. "Rubber
tires" generally refers to vehicular tires of the type used by
automobiles, tractors, etc.
[0035] As used herein, an "agricultural film" generally includes,
but it not limited to, a film formed from polyvinyl chloride (PVC),
polycarbonate (PC), a polyethylene thermoplastic resin, such as
polyethylene (PE), low density polyethylene (LDPE), or an
ethylene-vinyl acetate copolymer, or other such suitable films
formed from a polyester resin that may be used for forming, for
example, a greenhouse or a plastic tent, since such films exhibit
excellent transparency, heat-insulating ability, and mechanical
strength. These resin type films typically cannot be used for their
intended purpose for a long period of time because of deterioration
caused by UV rays, for example, impairment of transparency or
breakage of the film. Thus, they may be suitably cleaned and
shredded prior to being used in the recycled composite material of
the present invention.
[0036] The composite material may also include paper stock,
reclaimed "waste" paper (so-called recycled papers), de-inked paper
stock, paper shavings or cuttings, and the like. The reclaimed
papers may be shredded and included "as-is" or may otherwise be
mechanically disintegrated in water to produce a pulp suspension,
after which foreign materials may be removed. De-inked paper stock
may be used from printed and/or unprinted reclaimed papers by means
of mechanical disintegration, and may be treated with chemicals and
dispersing agents. In general, certain secondary pulps may be of
shorter fiber length and somewhat lower in strength than the
original pulp; therefore, they may be used either alone or
combination with prime or virgin fibers. Paper shavings and
cuttings (e.g., from binderies) may also be used.
[0037] In various embodiments, the composite material may include
recycled sanitary paper products. As used herein, "sanitary paper
products" may include various absorbent sanitary products, such as
disposable baby diapers, that can be separated into such products
suitable for use as a recycled material. Numerous treatment
processes for recovering usable portions of such items are known in
the art. For example, U.S. Pat. No. 5,558,745 to Conway et al.
discloses a treatment process for separating components suitable
for recycling from absorbent sanitary papers products and is
incorporated herein by reference in its entirety.
[0038] As previously discussed, the composite material of the
present disclosure may include a natural material, such as wood,
its shavings, or mulch in addition to the recycled nylon carpet and
other materials. As used herein, a "natural material" typically
includes wood, for example, material from a tree, including but not
limited to leaf material, branch material, trunk material, bark
material, needle material, and root material. As used herein, the
term "wood" includes, but is not limited to, any hard and soft wood
trees, and includes wood particles, fibers, strands, dust, scraps,
and products made there from. The wood particles used in the
present disclosure may be elongated shapes having a width or
average particle size that is about 1/4 (0.25) inch or less. In
various embodiments, the width is 1/16 (0.0625) inch or less, and
even more preferably, 1/32 (0.03125) inch or less. It should be
understood that the average particle size can be increased or
decreased, depending on the specific design and selection of
materials, and these variations are within the scope of the present
disclosure. It should further be noted that the average particle
size is not based on the total number of particles but rather is
based on the weight percentage of the material retained in
measuring sieve trays in relation to the total sieved material
weight. Natural material particles often have unequal dimensions,
for example a length greater than a width. In such circumstances, a
particle size refers to at least one dimension having the specified
size. Particle size distribution can be determined using Gaussian
distribution, or other methods known in the art.
[0039] Optional non-limiting additives for the composite material
may include colorants, UV protectors, flame and fire retardants,
lubricants, soaps, various inert fillers, reinforcements
(including, for example, natural, synthetic, and glass fibers),
polymerization initiators, coupling agents, and other additives
known in the art. Foaming agents may also be used to reduce overall
mass and save on raw materials and weight. Additionally, the
composite material is recyclable to itself as filler. In
particular, the use of coupling agents in the composite matrix may
improve thickness swell and increase the resistance to UV exposure
and surface popping. Coupling agents increase the bond between the
natural and plastic materials which typically increases the
stiffness and strength by up to about 30%. Alternatively, if it is
not desirable to use a coupling agent, the average particle size
can be slightly decreased to maintain an equivalent strength.
[0040] In certain embodiments, and preferably where the composite
material is used to manufacture sheet boards that are subsequently
cut into lead boards, it may be desirable to use larger size
recycled particles and include the use of reinforcing natural or
wood fibers. Such fibers may be used having an average length of
about 3/8 inch, 1/2 inch, 3/4 inch, or even greater as desired. In
various embodiments, it may also be desirable to include
continuous, uni-directional reinforcing fibers, such as
silicon-based fiberglass or other inorganic or organic fibers.
These continuous fibers would extend substantially parallel to and
run along with the direction of the cross-members to provide
additional strength.
[0041] The wood particles may be processed in a hammer mill using a
desired screen size. This enables distribution of the wood material
product in a substantially even manner for use with the recycled
components in the composite material. In various embodiments, the
particles have a random orientation in the final product, although
with some embodiments using extrusion techniques it may be desired
to have a process-specific orientation. Further, if reinforcing
fibers are used, it may be desired to align the fibers for
increased strength.
[0042] The manufacture of the composite material of the present
disclosure into various geometries is preferably achieved using
typical press methods, compression, injection molding, and/or
extrusion techniques known in the art. Typically, any wood or
natural materials are first passed through a mill to obtain a
desired particle size. The recycled and/or virgin plastic materials
are provided in a form suitable for mixing with the natural
materials, for example, in the form of a fluid, pellet, flake,
powder, or the like. In certain embodiments, the particles are
pre-densified before use. As will be discussed in more detail, in
one embodiment, the composite material is manufactured having a
board or panel geometry suitable for use as cross members and/or
lead board members for the upper and/or lower deck of the pallet.
In another preferred embodiment, the composite material is
manufactured having a block or post geometry for use as supporting
blocks that join the upper and lower decks to one another.
[0043] Typical press methods, if optionally used, rely on at least
one press and include suitable pneumatic, mechanical and/or
hydraulic presses that process wood/plastic mixtures into, for
example, a block or a composite board. As is known in the art, a
press typically includes an upper platen and a lower platen. At
least one platen is driven upward or downward by a drive mechanism.
A composite material assembly is positioned between the upper and
the lower platens. A typical composite material press assembly may
include a lower caul plate, a frame, the composite mixture and an
upper caul plate. According to one embodiment of the present
disclosure, at least one of the platens is heated to a temperature
sufficient to melt the plastic component of the composite material.
Heating of the platen(s) occurs optionally before or after
engagement of the drive mechanism. In one embodiment, both platens
are heated prior to application of pressure to the composite
mixture. Preferably, the drive mechanism drives the lower platen
upwards until the upper platen contacts the upper caul plate and
compresses the composite mixture.
[0044] The plastic components of the composite material mixture may
melt from the heat and disperse throughout the discontinuous wood
phase. The composite material may essentially form a slurry of
liquid plastic and wood particles. Preferably, air (and any other
gas that may be present) exits the composite mixture during this
process or it is alternatively compressed and trapped within the
slurry. The slurry is typically of a density greater than that of
the composite mixture and occupies a lesser volume than the
mixture. The slurry may then be cooled and forms a relatively rigid
composite product, such as a board. Rigidity and strength of the
final product will depend upon the thickness, the type of plastic
used, the ratio of natural and plastic materials, the amount and
pressure of any entrained gas, and whether a reinforcing material,
such as rods, bars, organic or inorganic continuous fibers, or a
mesh, is incorporated into the slurry. It should be understood that
caution is required when positioning the materials into the press
to avoid segregation of the wood and plastic materials. Minimized
segregation often forms a higher quality composite board.
[0045] In certain embodiments, any wood preparation methods and
press and/or extrusion methods can be combined into one production
process. For example, a wood receiver can be used for receiving
wood that is transported to a screen for screening out undesirable
larger pieces of wood. Once screened, the wood may be transported
to a reducer for reducing the size of the screened wood. The
reduced wood may be transported to a washer and/or screener that
can optionally include a re-chipper for further reduction of the
screened wood particle size. Next, the washed wood may be flaked
using an appropriate flaker and transported to a flake receiver
that optionally includes a heater and/or dryer and/or a dust
burner. Flakes may then be transported to a grinder for grinding
and/or sizing of the wood. The ground wood is then transported to a
sifter for sifting fines from larger pieces of wood. Fines are
transported to and stored in a fines receiver while the larger
pieces are transported to and stored in a processed wood receiver.
The fines receiver and processed wood receiver can optionally use
filters. The processed wood and/or fines are then ready for further
processing and/or combination with the recycled and/or plastic
components.
[0046] Recycled and/or plastic materials typically enter the
production process through a secondary receiver. The materials in a
secondary loader are optionally transported to a storage receiver
for storage and/or further processing. The storage receiver
optionally includes a filter. Once the recycled and/or plastic
material has been processed and/or stored, it is then transported
to a measurement system, for example, a weigh station system and/or
flow measurement system. The recycled materials, wood, and/or
plastic may be transported to a blender for blending the components
together. The blended components may be transported to a production
line that includes a press and/or an extruder. The production line
produces a final product or optionally has additional equipment for
performing additional steps for producing the final product. For
example, the production line can optionally include an unloader
and/or cooler; at least one trimmer and/or borer; at least one
transfer and/or inspection unit; a sander; a paint unit, for
example, for spray painting (if desired); an oven, for example, for
curing paint and/or other coating material; a grade station; and/or
a stacker, for stacking product.
[0047] As shown in FIG. 1 and generally referenced by the number
10, the pallet of the present disclosure has four peripheral sides
12, or edges, defining the perimeter. Preferably each side 12 is
disposed at a substantially right angle, thereby forming a
rectangular shape. In one preferred embodiment, the pallet is
constructed having the industry standard size and dimensions, which
is currently 40 inches wide by 48 inches long (1.0 m by 1.2 m),
although it may be made in any desired size or shape. The pallet 10
includes an upper deck 14 and a lower deck 16, each preferably
being formed of a plurality of longitudinally and laterally
extending cross members 18 and lead boards 19. As shown, the lead
boards 19 may be the same size as the remaining cross members 18,
or slightly larger to provide suitable additional strength.
Preferably, they have dimensions of about 51/2 inches wide, 40
inches long and 11/16 inches thick. Once assembled, the upper and
lower decks 14, 16 are held together with a plurality of separating
members, or blocks, generally referenced by the number 20.
[0048] As previously mentioned, at least one of the block members
20, and optionally certain cross members 18 of the decks, such as
the lead boards 19, comprise the high strength composite material
of the disclosure. For example, in certain embodiments, the block
members 20 comprise the composite material, and the cross members
18 are standard wooden pieces. In other embodiments, the block
members 20 and lead boards 19 comprise the composite material. In
still other embodiments, each member of the pallet 10 can comprise
the composite material. It should be understood that numerous
combinations and designs incorporating composite material blocks 20
and composite board cross members 18 and lead boards 19 are
possible, and all of the variations are within the scope of the
disclosure.
[0049] FIG. 2 depicts an exploded perspective view of the pallet 10
of FIG. 1, showing the individual components spaced apart from one
another, and which comprise the upper deck 14, the lower deck 16,
the cross members 18, and the plurality of blocks 20. Each block 20
holds the upper and lower decks 14, 16 together, while bearing and
distributing the cargo loads placed on the upper deck 14. In
preferred embodiments, the blocks 20 are mechanically fastened to
the upper and lower decks, for example, with nails or screws.
Preferably, there are nine blocks 20, aligned in three rows of
three, defining two apertures 22 on each side 12 of the pallet 10.
Ideally, each pallet has four corner blocks 24, four mid-side
blocks 26, and one center block 28. The size of the apertures 22
will depend upon the size and length of the blocks 20.
[0050] In various embodiments, the upper deck 14 defines a
generally planar load bearing surface upon which objects and goods
may be positioned for transport and storage. The lower deck 16
defines a substantially planar bottom surface for the secure
placement of the pallet on the ground or other resting surface.
This also allows for the stable stacking of the pallet onto a
similarly designed pallet. In certain embodiments, the upper and/or
lower decks 14, 16 can comprise a continuous sheet of material (not
shown). In these embodiments, a number of indentations and
projections such as ridges and channels (not shown) may be formed
in the top of the upper deck to allow for the drainage of any
liquids that may accumulate thereon. Alternate embodiments may
include further channels configured to direct fluid to the sides of
the pallet if necessary. It should be noted, however, that the
number, orientation, size and shape of any ridges or channels can
be varied in many alternate configurations for optimized strength.
Of course, the upper or lower deck 14, 16 may also have a
continuous surface without apertures if so desired.
[0051] The load bearing surface may have a texture or an etched or
imprinted geometrical pattern thereon (not shown) that acts as a
non-skid surface to prevent objects from sliding during transport.
Alternatively, any suitable type of friction tape or friction
coating may be applied or laminated to the load bearing surface in
order to help prevent movement of objects on the pallet. The final
pallet assembly may additionally be embossed, silk screened,
painted, or printed with indicia such as graphics, text, codes,
brands, or the like if so desired.
[0052] Preferably, the lower deck 16 includes longitudinally and
laterally extending cross-members aligned and connected to form a
substantially rectangular shaped outer frame. As shown, one
arrangement of the cross-members includes two relatively large
apertures 38 allowing air flow through the pallet and also for
accommodating pallet jacks. While shown as substantially
rectangular in shape, the apertures 38 may be sized and shaped for
other desired applications. Additional cross-members may be used,
depending upon the desired load capacity of the pallet 10. In
alternate embodiments, the size and number of apertures 38 will
depend upon the placement and number of cross-members used.
[0053] Preferably, the blocks 20 are of a sufficient size so that
the apertures 22 define a space suitable for access by the tines,
or forks, of a forklift truck or pallet jack from any of the four
sides 12 of the pallet 20. The current industry standard is to have
apertures 22 with a separation distance D of about 3.5 inches
between the upper deck 14 and lower deck 16. Thus in one embodiment
as shown in FIGS. 3-5, the blocks have a height H of about 3.5
inches, a width W of about 3.65 inches, and a length L of about
4.75 inches. For additional impact resistance, the blocks 20 may be
provided with curved ends, thereby minimizing potential damage
which may occur upon collision or brunt contact. Depending upon the
specific composite material and desired strength, small to medium
size blocks 20 may vary in weight from about 0.5 to about 5 lbs or
more, and preferably from about 1 to about 2 lbs, or about 1.5 lbs.
The blocks 20 may have a volume of from about 25 to about 75
in.sup.3 or more, and preferably from about 40 to about 60
in.sup.3, or about 55 in.sup.3. In other embodiments, it may be
desirable to use larger scale blocks, for example having a volume
of from about 75 to about 130 in.sup.3 or more, and preferably from
about 110 to about 125 in.sup.3. These would typically have a
weight of from about 4 to 5 lbs.
[0054] As shown in one non-limiting embodiment illustrated in FIGS.
3-5, the blocks 20 may have an elongated elliptical shape,
including a planar top surface 30, a planar bottom surface 32, and
two substantially circular side sections 34 sandwiching a
substantially flat section 36. FIGS. 6-8 illustrate another
embodiment of a block member 20 according to the present
disclosure. As best shown in FIGS. 6 and 7, the block members 20
may be provided with a plurality of alternating vertical channels
37 and ridges 38. In various designs, the channels may have a depth
of between about 0.05 to about 0.2 inches, while the number and
width of the channels 37 and ridges 38 will vary based upon the
total dimensions of the block member 20. FIGS. 9-11 illustrate
still another embodiment of a solid block member 20 having a
substantially square top 40 and cross-section with substantially
rounded exterior corner areas 42. FIGS. 12-14 illustrate yet
another embodiment of a hollow block member 20. As shown, the block
member is provided with a substantially rectangular shaped top 44
with rounded corner areas 42 and having a hollow center area 46.
FIG. 15 illustrates a variation of the embodiment of FIG. 6 and
shows a block member having a plurality of alternating horizontal
channels 37 and ridges 38. It should be understood that the
specific size and shape of the composite block members 20 may be
modified as necessary and desired, and variations of the overall
size and shape are within the scope of the present disclosure.
[0055] The description of the disclosure is merely exemplary in
nature and, thus, variations that do not depart from the gist of
the disclosure are intended to be within the scope of the
disclosure. Such variations are not to be regarded as a departure
from the spirit and scope of the disclosure.
* * * * *