Abstract:
A molded shipping pallet is set forth as well as a process for molding and composition therefore. The process includes pre-heating and mixing various meshes of ground, crumb rubber with other polymers and agents and introducing the composition into a mold to mold the pallet. The pallet is molded to have a shape and construction which minimizes weight yet provides strength.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a method for molding, composition and synthetic pallet of the type used to support goods for lifting using a forklift and for shipping. 
     BACKGROUND OF THE INVENTION 
     In the past, lifting and shipping pallets were manufactured from wood. The wood was typically nailed together to form top and bottom surfaces separated by a network of supporting braces. Goods, such as stacked material, would be loaded on the top surface. To lift and move the goods on the pallet, a forklift would position its lifting forks between the top and bottom surfaces and lift the pallet and goods as a unit. In most cases the wooden pallets were constructed such that the top and bottom surfaces were similar so that the pallet could be used in the same manner without regard to whether the pallet was upside-down (the bottom surface is on the top) or right-side up. 
     A drawback to wooden pallets is that they are subject to breakage. If the wooden planks used to construct the top surface break the pallet becomes, for the most part unusable. A further drawback is that wooden pallets can wear and degrade over time making them unusable. Still a further drawback is that often the wooden pallets are non-uniform resulting in some not being usable whatsoever. Still another drawback is that wooden pallets do not have a long service life. Rough handling, environmental factors drying or rotting the wood, pest infestation all contribute to a shortened service life for wooden pallet. Still further, the construction of wooden pallets consumes resources, i.e. wood which, while being a replenishing resource, is nonetheless a resource which should be conserved for more beneficial uses. 
     There is a need for a stronger, more durable, and more uniform pallet. 
     In Radke, Jr. U.S. Pat. No. 6,374,753 issued Apr. 13, 2003 there is disclosed a cold formed synthetic pallet. According to this patent discarded tires are shredded and mixed with shredded plastic and an epoxy binder. The materials are mixed to coat the shredded products and the mixture is poured into a pallet mold and compressed until the binder cures, adhering the products together in the shape of pallet mold. 
     The quality of the molded pallet described above is related to the proper mixing of the materials and binder in proper quantities. Too little binder and there is inadequate coverage of the shredded pieces which may result in areas of weakness in the finished product. Too much binder can result in extended curing times and a weakened finished product. 
     Still further, the finished pallet can be weakened or rejected if the materials are not properly shredded. Too large of shredded pieces can weaken the pallet. Too small of pieces and larger amounts of binder must be used. 
     Further, it is submitted that outdoor exposure to ultraviolet light may tend to degrade the pallet. 
     There is a need for a process for manufacturing a molded pallet, a composition therefore and a product produced by the process. 
     SUMMARY OF THE INVENTION 
     There is, therefore, set forth according to the present invention a molded pallet which is inexpensive to manufacture, which can be molded from products including scrap tire thermoplastic products, thereby contributing to environmental quality be reducing landfill waste by recycling, which has increased strength, durability and service life and which presents a vertical profile smaller than traditional wooden pallets to reduce wasted vertical space. 
     Toward this end, there is set forth a process for molding a pallet which includes mixing, in a heated chamber, crumb rubber of different size grades with ground thermoplastic, a foaming agent, a ground Kraton® polymer and a plastic adhesive. The mixing in the heated chamber is continued for a period to thoroughly mix the components. Heating in the mixing chamber is insufficient to fluidize the composition or cause the components to significantly soften. The mixed composition is then allowed to cure (cool) and then may then be bagged or packed for shipment. 
     The composition is then heated to a fluid state and provided as by gravity or powered injection into a mold cavity configured to define the pallet. The configuration preferably defines a square or rectangular pallet having a substantially flat top surface, and a bottom surface with depending legs to position the bottom surface above a floor sufficient to accommodate the forks of a forklift for lifting the pallet and goods positioned thereon. To add strength to the pallet the bottom surface may include a crises-cross or honeycomb pattern of webbing there along. 
     The materials of composition may include crumb rubber of different mesh grades which provides for varying particle sizes in the composition. The Kraton® polymer adds strength and resistance to ultraviolet degradation whereas the thermoplastic, foaming agent and adhesive define a binder for the composition which, when the composition is heated to a fluid state, expand and adhere the composition products for the desired results. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  graphically represents the mixing of the composition materials for future use; 
         FIG. 2  is a top view of a molded pallet; 
         FIG. 3  is an illustrative view of the bottom of the molded pallet; 
         FIG. 4  is a side view of the molded pallet; and 
         FIG. 5  is a bottom-side perspective view of the pallet. 
     
    
    
     DESCRIPTION 
     Reference is now made to the figures wherein like parts are referred to by like numerals throughout. Turning to the drawings,  FIG. 1  shows the process for forming a pallet  10  according to the present invention. At  12 ,  14 ,  16  and  18  various mesh of ground rubber (e.g. from discarded tires), is assembled. Optionally, the percentages of the mesh rubber are as set forth below:
         10 Mesh Crumb Rubber 35% (by volume)   20 Mesh Crumb Rubber 18.5%   30 Mesh Crumb Rubber 10%   40 Mesh Crumb Rubber 8%
 
The percentages of the contribution by volume of the carious meshes of crumb rubber may be altered. For example, in an optional embodiment, a plurality of different size crumb rubber is used with the largest size being approximately 10 Mesh and the smallest being approximately 20 Mesh.
       

     The crumb rubber components are vigorously mixed for a period of time, e.g. 24 hours, in a pre-heat chamber  19  to assure complete mixing of the rubber based component. After mixing of the rubber in the pre-heat chamber the other components are added at  20 ,  22 ,  24 ,  26  and  27  as follows: 
     
       
         
               
               
             
           
               
                   
               
             
             
               
                 High Density Polyethylene 
                 14.5% 
               
               
                 Thermoplastic elastomer in the 
                 6.5% (Kraton is a Registered Trade- 
               
               
                 form of a styrenic block copolymer 
                 mark of the Shell Oil Company) 
               
               
                 or isoprene rubber such as 
               
               
                 Kraton ® 
               
               
                 Thermoplastic elastomer or 
                 4.5% (Santoprene ® is a registered 
               
               
                 thermoplastic vulcanizate such as 
                 Trademark of Advanced Elastomer 
               
               
                 Santoprene ® 
                 Systems, L.P.) 
               
               
                 Exothermic or endothermic 
                 2% (Foamazol ® is a Registered 
               
               
                 chemical foaming agent such as 
                 Trademark of Richard B. Leahy) 
               
               
                 Foamazol ® 
               
               
                 Aliphatic hydrocarbon or 
                 1% (Struktol ® is a Registered 
               
               
                 hydrocarbon resins plastic adhesive 
                 Trademark of Schill &amp; Seilacher 
               
               
                 such as Struktol ® 
                 GmbH &amp; Co) 
               
               
                   
               
             
          
         
       
     
     The crumb rubber with the additional components is then mixed in the pre-heat chamber for an additional period of time, e.g. 24 hours. The mixture, by the heating of the pre-heat chamber is fluidized so that thorough mixing of the components can take place. The fluid mixture can then be pelletized, cooled and bagged at  31  for future use. Alternatively the fluid mixture can be sent directly to the molding stage  28  of the process. 
     Assuming that the compound mixture has been pellitized, at  30  the pellets are introduced into a heated chamber which heats the pellets to a fluid state and at a sufficient temperature to render the composition flowable. At  28  the composition is poured or injected into a pallet mold to form the composition into the desired shape, such as the shape described herein. After the mold has cooled to the point that the composition is solid, at  32  the molded pallet is ejected from the mold, permitted to cool and is ready for use. 
     While the pallet may have any desired shape and construction, including single-piece construction or multiple-piece construction. In an optional embodiment the composition is molded into the shape shown in  FIGS. 2–5 . The pallet  10  has a substantially flat top surface  40  defined by a plurality of parallel arranged slats  42  separated by elongate gaps  41  to permit rain and moisture to drain from the top surface  40 . Sides  44   a, b  depend from the top surface  40  and are separated by ends  46   a, b . The sides  44   a, b  are configured by the shaping of the mold to define end legs  48   a, b  and a medial support  50  creating gaps  52  of a size to pass pallet forks of a typical pallet hoist. Further the legs  48   a, b  and medial support  50  act to space the top surface  40  above the ground to receive the forks of a pallet hoist thereunder. 
     To further provide support to the pallet  10  at least one lateral support  54  may optionally extend between the ends  46   a, b  and between the sides  44   a, b  along the bottom  56 . The lateral support  45  further has defined legs  48   a, b  and a medial support  50  aligned with a complimenting the legs  48   a, b  and medial supports  50  of the sides  44   a, b.    
     The top surface  40  has a predetermined thickness. To provide support for the top surface  40 , along the bottom  56  thereof at molded webbing or brace network  58  which may be defined by of a criss-cross or honeycomb pattern of bracing as suggested in  FIGS. 3 and 5 . The brace network  58  provides strength to the pallet  10  which reducing the weight thereof. 
     While certain embodiments of the present invention have been shown and described it is to be understood that the present invention is subject to many modifications and changes without departing from the spirit and scope of the claims presented herein.