Abstract:
An enhanced polymeric void board for placement between adjacent horizontal layers of masonry materials to maintain an opening in a lower of the layers, the enhanced void board comprising a relatively thin planar element having a plurality of ribs extending along the length of the planar element.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to an enhanced polymeric board used as a void board. More particularly, the present invention relates to a fabricated, topologically reinforced and static-reduced void board for use in forming bundles of uniform masonry materials such as bricks. 
         [0002]    Bricks, or other masonry materials, are typically bundled as a plurality of stacked individual units (i.e., individual bricks) formed into a 3-dimensional bundle. The bundle includes one or more package straps, corner protectors, and a void board that is placed between two horizontal layers of bricks. Generally, the void board is placed above a layer of bricks that has bricks omitted, e.g., forming two apertures in the bundle. Additional layers of bricks are placed on top of the board. The apertures, which are typically centrally disposed, are configured to allow the prongs of a forklift or similar device to pass into the bundle. In moving the package of bricks, the forklift exerts a force on the underside of the board, to lift the entire package. Typically, the apertures are formed extending through the entire depth of the bundle. 
         [0003]    One known void board is formed as a veneer. These veneer void boards are often of poor quality and have a tendency to warp. Warping results in uneven surfaces upon which layers of bricks are stacked, which in turn can result in package instability. Moreover, veneer void boards do not allow clean “separation” of the brick layers (in the depth direction) from the bundle, in that 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. 
         [0004]    Other void boards use solid or ribbed plastic sheets. Such void boards are disclosed in Duke et al., U.S. Pat. No. 6,989,184 and in Varma, et al., U.S. patent application Ser. No. 11/156,331, both commonly assigned with the present application and incorporated herein by reference. While void boards have been found to function well at a given thickness, they require a higher material weight (and thus, cost) than desired for such a consumable item. When a thinner sheet is used (and thus, less material), it has been found that the boards may not have the desired stiffness. 
         [0005]    Accordingly, there is a need for a void board that is of consistent quality, reliability, 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 and readily separable from other void boards. More desirably, such a void board endures environmental conditions without warping. Most desirably, such a void board is fabricated or manufactured such that a lesser weight of material is used to provide a sufficiently stiff board. 
       SUMMARY OF THE INVENTION 
       [0006]    An enhanced polymeric void board is configured for placement between adjacent horizontal layers of masonry materials, such as 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. 
         [0007]    The enhanced void board is fabricated from a relatively thin, planar element having a plurality of ribs extending along the length of the surface of the planar element. The enhanced void board is fabricated by extruding a base material in sheet form and embossing the extruded material such that the result resembles ribs. The extruded void board is then cooled. 
         [0008]    In one embodiment, the ribs are formed in parallel rows, extending longitudinally along the length of the enhanced void board, wherein the on-center distance between adjacent ribs is approximately 2.250 inches. Holes can be formed in the enhanced void board in the spaces defined by the ribs. 
         [0009]    In an alternate embodiment, the extruded material may be embossed in a cross-hatch pattern, defining a diamond-shaped space. Holes can be positioned within the diamond-shaped spaces. It is understood that any variation or pattern of ribs of the enhanced void board seeking to strengthen the product while reducing part of the weight is in the spirit of the invention. 
         [0010]    Optionally, the enhanced void board can be fabricated with weakened regions formed in the board, generally parallel to the ribs and aligned with one another. This provides a plurality of frangible regions for separating a portion of the enhanced void board from another portion of the enhanced void board such that the masonry materials, which rest on the enhanced void board, may also be easily separated from the group of materials. 
         [0011]    The enhanced void board can be extruded from polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), polystryrene (PS), polyethylene (PE), and other similar polymers and blends thereof. In addition, enhanced void board may be extruded from filled polymers, including, but not limited to paper fiber, wood fibers, and minerals. 
         [0012]    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 
         [0013]    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: 
           [0014]      FIG. 1  is a perspective view of a bundle of bricks having an enhanced void board embodying the principles of the present invention disposed between horizontal layers of bricks; 
           [0015]      FIG. 2  is a perspective view of one vertical layer of bricks separated from the bundle of  FIG. 1 ; 
           [0016]      FIG. 3  is a top view of one embodiment of the enhanced void board of the present invention; 
           [0017]      FIG. 3A  is an alternate embodiment of the void board similar to that shown in  FIG. 3 ; 
           [0018]      FIG. 4  is a side view, as indicated in  FIG. 3 , illustrating the rib and board end profile; 
           [0019]      FIG. 5  is a top view of an alternate embodiment of the void board (with cross-hatch pattern); 
           [0020]      FIG. 5A  is a top view of an embodiment of the void board similar to that shown in  FIG. 5 ; 
           [0021]      FIG. 6  is an enlarged view of the board of  FIG. 5 , illustrating the rib and board profile; and 
           [0022]      FIG. 6A  is a view similar to that of  FIG. 6  illustrating the void board of  FIG. 5A   
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    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. 
         [0024]    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. 
         [0025]    With reference now to the figures and in particular to  FIG. 1 , a bundle  10  of bricks is shown with one embodiment of an enhanced void board  12  in accordance with the principles of the present invention. The bundle  10  is a 3-dimensional stack of individual bricks  14  that form a matrix with a plurality of horizontal layers, e.g.,  16   a - 16   j . The stack  10  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. 
         [0026]    The bundle  10  is maintained in the 3-dimensional configuration by straps  18  that are positioned about the bundle  10 . In a typical bundle  10 , vertical straps (in the y-direction) are positioned around the bundle  10  extending in both the x and z-directions. Horizontal straps can be, but generally are not 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. The corner protectors  20  also preclude strap  18  failure due to, for example, abrasion. 
         [0027]    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. 
         [0028]    To maintain the layer  16   d  of bricks  14  above the opening  22 , the enhanced void board  12  is placed between the horizontal layers  16   c  and  16   d  of bricks  14 , that is, above the layer  16   c  in which the openings  22  are formed. One embodiment of the enhanced void board  12  is illustrated in  FIGS. 3 and 4 . The board  12  is fabricated as an extruded base element  30 . The element  30  has a thickness t b  of about 0.063 inches. A plurality of ribs  32 ,  34  extend longitudinally along the length l 10  of the void board  12  to a height h r  of about 0.063 inches from a first surface  15 . In a present board  12 , the ribs  32 ,  34  are parallel and are generally equal in height. 
         [0029]    In a present embodiment, the board  12  has an overall thickness t 0  (including the thickness of the base element and the height of the ribs) of about 0.125 inches. The ribs  32 ,  34  have a width w r  of about 0.500 inches and are spaced s r  from adjacent ribs about 2.0 inches apart and preferably about 2.250 inches on center. 
         [0030]    An alternate embodiment  12 ′ of the straight ribbed void board is shown in  FIG. 3A . In this embodiment  12 ′, holes  28 ′ are fabricated in the board  12 ′ between the ribs  32 ′,  34 ′ of board  12 ′. The holes  28 ′ can be located longitudinally along board  12 ′ in the same location in each board or the longitudinal location can vary among boards. The holes  28 ′ provide an opening through which air can move as a board  12 ′ is lifted from a stack of boards. The air will tend to create resistance to “lifting” of the next lower board and thus tend to facilitate grasping and moving single boards at a time. The holes  28 ′ also reduce the negative pressure region that is created below the board  12 ′ as it is grasped and pulled upward, also reducing the potential for grasping more than one board at a time. This tends to reduce the effect of static electricity or other “sticking” inherent in thermoplastic materials and to allow for easier lift and separation of the thermoplastic sheets or boards  12 ′ from one another prior to insertion into bundle  10 ′, 
         [0031]    An alternate embodiment of the void board  112  is illustrated in  FIGS. 5 and 6 . In this embodiment, the board  112  is extruded and embossed such that the extruded material has a ribbed cross-hatch pattern defining a diamond shape, as shown generally at  132 ,  134 . This configuration of the board  112  produces an apparent thick ribbed sheet. The spaces defined by the cross-hatching of the ribs  132 ,  134  provide a plurality of diamond-shaped void spaces  144 . The enhanced void board has an overall thickness t oa  (including the thickness of the base element  130  and the height of the ribs) of about 0.125 inches. The ribs,  132 ,  134  have a width of about 0.500 inches and are cross-hatched to form diamond-shaped void spaces  144  with curved corners. The centers of the diamond-shaped spaces are regularly spaced approximately 3.000 inches apart. A first inner diagonal dimension  136  of the diamond-shaped void spaces measures about 2.500 inches and a second inner diagonal dimension  138  of the diamond-shaped void space measures about 4.375 inches. A third outer diagonal dimension  139  of the diamond-shaped void space  144  measures about 6.000 inches. 
         [0032]    An alternate embodiment  112 ′ of the diamond pattern board is illustrated in  FIGS. 5A and 6A . In this embodiment  112 ′, holes  128 ′ are formed In the void spaces  144 ′ which reduce the effect of static electricity and facilitate lift and separation of the board  112 ′ from adjacent boards  112 ′. The holes  128 ′ can be centered within the diamond spaces  144 ′, in a uniform repeating pattern. 
         [0033]    Advantageously, in all of the embodiments, the strength of the board  12 ,  12 ′,  112 ,  112 ′ is preserved even with less material used to fabricate the sheet. This is accomplished by providing structural shapes to define the board. 
         [0034]    Optionally, the enhanced void board  12 ,  12 ′ can be formed having one or more weakened, frangible regions  48 ,  48 ′ formed in the enhanced void board  12 ,  12 ′. The weakened regions  48 ,  48 ′ can be made by forming a score, crease or perforation in the board  12 ,  12 ′. The weakened regions  48 ,  48 ′ extend parallel to and between the ribs  32 ,  34 ,  32 ′,  34 ′. The weakened regions  48 ,  48 ′ permit separating the enhanced void board  12 ,  12 ′ cleanly between aligned ribs  32 ,  34 ,  32 ′,  34 ′ and within the same void space  44  after, for example, the bricks forming a vertical layer  50  of the bundle  10  (see  FIG. 2 ) are removed. In this manner, the remaining board is not extending out beyond the bundle  10  as would be with a solid sheet. It is understood that frangible regions also may be formed in alternate embodiments with alternate rib configurations and intended to fall within the spirit and scope of the present invention. 
         [0035]    The board  12 ,  12 ′,  112 ,  112 ′ can be formed from a wide variety of readily available materials. A present board  12 ,  12 ′,  112 ,  112 ′ is made from a low melt-strength, inexpensive polymeric material and each board  12 ,  12 ′,  112 ,  112 ′ is, preferably, an extruded member. Anticipated materials include polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), polystryrene (PS), polyethylene (PE), and other similar polymers and blends thereof. Those skilled in the art will appreciate these and other suitable materials. 
         [0036]    In addition to the enhanced stability and reduced “crush” afforded by the present void board  12 ,  12 ′,  112 ,  112 ′, an additional benefit of the present board is the ability to remove a vertical brick layer  50  (removed perpendicular to the direction of the fork prong openings  22  as seen in  FIG. 2 ), without having to contend with static electricity or other adhering qualities of the polymeric material. 
         [0037]    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” or “an” object is intended to denote also one of a possible plurality of such objects. 
         [0038]    All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
         [0039]    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.