Abstract:
An extruded polymeric void-board is configured for placement between adjacent horizontal layers of bricks to maintain an opening in a lower layer of the bricks. The void-board is formed as a relatively thin planar element having first and second surfaces. A plurality of parallel ribs extend from and generally transverse to the first side. The ribs have a predetermined height to width ratio and have a height that is less than a thickness of the planar element. The ribs being formed parallel to one another. A method for forming a bundle of bricks with the void-board is also disclosed.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates generally to a polymeric board used as a void-board. More particularly, the present invention relates to a profile-extruded void-board for use in forming bundles of bricks. 
   Bricks are typically “packaged” as a plurality of stacked individual units (i.e., bricks) formed into a 3-dimensional bundle. The bundle includes one or more package straps, corner protectors, and a veneer void-board, which is placed between two horizontal layers of bricks. Generally, the veneer void-board is placed above a layer of bricks that has bricks not present, e.g., forming two holes in the bundle. Additional layers of bricks are placed on top of the veneer board. The holes, which are typically centrally disposed, are configured to allow the prongs of a forklift or similar device to pass into the bundle. To move the package of bricks, the forklift will exert a force to the underside of the veneer, to lift the entire package. Typically, the holes are formed extending through the entire depth of the bundle. 
   Known void-boards have a number of drawbacks. For example, veneer void-boards are often times of poor quality. Known veneer boards have a tendency to warp. Warping and the attendant uneven surfaces upon which layers of bricks are stacked can result in package instability, and as a result, difficultly in package formation. In addition, known void-boards do not allow clean “separation” of the brick layers (in the depth direction) from the bundle. That is, there is no easy way to separate the bricks and sever or cut the board at the juncture of that layer and the remainder of the brick bundle. One solution explored in the past was to use a corrugated plastic sheet. However, the corrugated sheets tended to be crushed by the weight of the bricks. As a result the corrugated sheets were found to buckle in use. 
   Accordingly, there is a need for a void-board that is of consistent quality, consistency and strength to allow stable stacking of bricks for bundle forming without crushing the board. Desirably, such a void-board is readily severed for separating layers of bricks. Most desirably, such a void-board endures environmental conditions without warping. 
   SUMMARY OF THE INVENTION 
   An extruded polymeric void-board is configured for placement between adjacent horizontal layers of bricks to maintain an opening in a lower layer of the bricks. The opening is configured for insertion of a prong of a forklift for transporting the bundle of bricks. 
   The void-board is a relatively thin planar element having first and second surfaces. A plurality of parallel ribs extend from and are generally transverse to the first side. The ribs have a predetermined height to width ratio and have a height that is preferably less than a thickness of the planar element. The ribs are formed parallel to one another. The present void-board has a consistent quality, consistency and strength and allows stable stacking of bricks for bundle forming without crushing the board. 
   In a present void-board, the ribs are formed extending only from the first side of the planar element. The ribs are curved, having a semi-cylindrical profile. A present board has ribs that are formed on an on-center distance or spacing of about 0.10 inches to about and 0.20 inches, and preferably about 0.14 inches. The height to width ratio of the ribs is about 0.5. 
   Optionally, the void-board includes weakened regions formed in the planar element generally parallel to the ribs, between selected ones of the ribs. The weakened regions provide a plurality of frangible regions for separating the board. This permits separating vertical layers of bricks while maintaining the overall integrity and stability of the brick bundle. 
   Most desirably, such a void-board endures environmental conditions without warping. To this end, a present board is formed from polypropylene, polyethylene and a filler material. In one composition, the polyethylene is a linear low density polyethylene and the filler material is a cellulose fiber material. 
   A preferred composition is about 50 percent to about 80 percent polypropylene, about 20 percent to about 40 percent linear low density polyethylene and about zero percent to about 10 percent cellulose fiber filler material. More preferably, the board is about 65 percent polypropylene, about 30 percent linear low density polyethylene and about 5 percent filler material. 
   A method for forming and separating a bundle of bricks with the void-board is also disclosed. 
   These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
       FIG. 1  is a perspective view of a bundle of bricks having a void-board embodying the principles of the present invention disposed between horizontal layers of bricks; 
       FIG. 2  is a perspective view of one vertical layer of bricks separated from the bundle of  FIG. 1 ; 
       FIG. 3  is a side view of the void-board of the present invention; and 
       FIG. 4  is an enlarged view, as indicated in  FIG. 3 , illustrating the rib and board end profile. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   While the present invention is susceptible of embodiments in various forms, there is shown in the drawings and will hereinafter be described some exemplary and non-limiting embodiments, with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
   It should be understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
   Referring now to the figures and in particular to  FIG. 1 , there is shown a bundle of bricks  10  having a void-board  12  embodying the principles of the present invention. The bundle  10  is a 3-dimensional stack of bricks  14  (forming a matrix) that includes a plurality of horizontal layers, e.g.,  16   a – 16   j . The stack thus defines a length l 10 , a height h 10  and a width w 10 , which are represented by the x, y and z-axes as shown. 
   The bundle  10  is maintained in the 3-dimensional configuration by straps  18  that are positioned about the bundle  10 . Vertical straps  18  (in the y-direction) can be positioned around the bundle extending in both the x and z-directions. Horizontal straps may not be used. Corner protectors  20  are disposed along the corners of the brick bundle  10  between the bricks  14  and strap  18  to protect the bricks  14  from damage due to rubbing and accidental bumping and to protect the strap  18  from failure due to, for example, abrasion. 
   In order to readily transport the bundle  10 , openings  22  are formed in the bundle  10  by removing or eliminating bricks in a predetermined area of the matrix. The openings  22  are configured to permit the insertion of the prongs of a forklift. In this manner, the prongs can be inserted into the openings  22  and the bundle  10  raised and transported as desired. 
   To maintain the layer of bricks  16   d  above the opening  22 , the void-board  12  is placed between the horizontal layers  16   c  and  16   d  of bricks, i.e., above the layer  16   c  in which the openings  22  are formed. An embodiment of the void-board  12  is illustrated in  FIG. 3 , which shows a profile of the polymeric void-board. The board  12  has a planar base element  24  having a thickness t 24  and includes a plurality of ribs  26  extending outwardly from the planar element  24 . In a present board  12 , the ribs  26  are parallel and are generally equal in height h 26  or distance from the planar base element  24 . A terminal end  28  of each rib defines a peak  30 . In a present embodiment, the ribs  26  are substantially solid, and the peaks  30  are rounded. In a present board  12  the base element has a thickness t 24  of about 0.025 inches to about 0.065 inches, preferably about 0.035 inches to about 0.045 inches, and most preferably about 0.040 inches. 
   The ribs  26  are formed having a semi-cylindrical profile extending along the surface  32  of the board  10 . The ribs  26  have a radius R 26  of about 0.030 inches (and thus a height from the surface  32  of about 0.030 inches) and are formed at a spacing S 26  of about 0.10 to about 0.30 inches and preferably about 9/64 (0.14 inches) inches on center. Because the ribs  26  have a semi-cylindrical profile, the have a height h 26  to width w 26  ratio of about 0.5. The total thickness t 10  of the board  10  (the planar element  24  and the ribs  26 ) is thus about 0.070 inches, and at least 0.040 inches. A back end corner  34  of the board  10  (at the board end, opposite of the end rib) has a rounded profile with a radius of about 0.020 inches. It is anticipated that rib  26  configurations can be of many different sizes and shapes with a wide variety of height to width ratios, all of which are within the scope and spirit of the present invention. 
   Optionally, the void-board  12  can be formed having one or more weakened regions  36  formed in the planar element  24 . The weakened regions  36  can be made by forming a score, crease or perforation in the element  24 . The weakened regions  36  extend parallel to and between the ribs  26 . The weakened regions  36  permit separating the board  12  after, for example, the bricks forming a vertical layer  38  of the bundle  10  (see  FIG. 2 ) are removed. In this manner, the remaining board  12  is not extending out beyond the bundle  10  as would be with a solid sheet. 
   A present board  12  is formed from polyolefin blends with various fibrous or particulate filler materials. A present board is polypropylene (PP), linear low density polyethylene (LLDPE), and a filler material such as cellulose fibers. A preferred composition is about 50 percent to about 80 percent PP and about 20 percent to about 40 percent LLDPE. A more preferred composition is about 30 percent to about 40 percent PP, about 25 percent to about 35 percent LLDPE, and about 2 percent to about 8 percent cellulose. Most preferred is a composition of about 65 percent PP, about 30 percent LLDPE, and about 4 percent cellulose. 
   The void-board  12  is preferably an extruded member and, as such, the ribs  26  are formed integral with the planar element  24  (body) of the board  12 . A present board  12  is formed having a density of about 0.7 grams per cubic centimeter (gm/cc) to about and 1.3 gm/cc, preferably about 0.85 gm/cc to about 1.15 gm/cc and most preferably about 1 gm/cc. It should be noted that 1 gm/cc is equal to a specific gravity of about 1.0. It is contemplated that the ribs  26  are formed in the machine direction of the board  12 , e.g., as the board  12  is extruded, to facilitate manufacture. Such manufacture also results in a high strength board  12 . 
   As seen in  FIG. 1 , the bundle of bricks  10  is maintained as a bundle by the straps  18 , corner protectors  20 , and void-board  12  embodying the principles of the present invention. The bricks  14  are arranged side-by-side to form a first horizontal layer  16   a . Additional horizontal layers  16   b – 16   j  can be disposed above the first layer  16   a . One of the layers, e.g.,  16   c , is then positioned on the stack with one or two rows of bricks removed, thus forming the sides and bottom of the fork lift prong openings  22 . The void-board  12  is positioned on the open row layer  16   c , and a full horizontal layer  16   d  of bricks is disposed on the void-board  12 . The void-board  12  is positioned on the layer  16   c  such that the ribs  26  are perpendicular to the (longitudinal direction of the) fork prong openings  22 . The ribs  26  are positioned downwardly, resting on the top of the lower layer  16   c  of bricks (as oriented in  FIG. 3 ). Additional horizontal layers can be positioned on the layer  16   d  that is positioned on the layer overlying the void-board  12 . Corner protectors  20  are positioned on the bundle  10  and the bundle  10  is strapped (with strap material  18 ) to secure the bundle  10 . 
   In addition to the enhanced stability and reduced “crush” afforded by the present void-board  12 , an additional the benefit of the present board  12  is the ability to remove a vertical layer of bricks  38  (removed perpendicular to the direction of the fork prong openings as seen in  FIG. 2 ), and to retain the board  12 , in a clean-cut condition by separating along one of the weakened regions  36  to maintain the integrity of the remainder of the brick bundle  10 . 
   In the disclosure, the use of the disjunctive is intended to include the conjunctive. The use of the definite article or indefinite article is not intended to indicate cardinality. In particular, a reference to “the” object or “a” object is intended to denote also one of a possible plurality of such objects. 
   All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
   From the foregoing it will be observed that numerous modification and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.