Abstract:
A tray and slip sheet system for transporting aggregated bales of rubber that provides a manner for thawing rubber being transported, that prevents large rubber bales being transported from fusing together, and that does not damage or contaminate the packaged rubber when a forklift&#39;s forks are inserted between two stacked aggregated bales using the tray and slip sheet system. The tray and slip sheet system uses a tray sheet, a slip (when transporting more than one stacked aggregated bale of rubber), and a strap securing system. The tray and slip sheet system provides a system that defines an air recirculation system that allows the first two levels of bales of rubber stacked over the footprint to be defrosted in hot air chambers after winter transport. Systems not having ventilation slits do not allow the first two levels of bales being transported from being completely defrosted.

Description:
BACKGROUND 
       [0001]    The present invention relates generally to a tray and slip sheet system used to transport aggregated bales of rubber. The system uses recyclable materials and eliminates the need of the use of wooden pallets during the transport of rubber. 
         [0002]    The tray and slip sheet system provides a means for arranging aggregations of small rubber bales into larger rubber bales that can be stacked and transported without the fear of the larger rubber bales being fused together. The larger rubber bales can weigh up to 1.26 metric tons, and as is known in the industry, if rubber is stacked up on each other, after a certain period of time, the rubber will fuse together, provided that enough force is applied at the juncture of the stacked rubber bales. 
         [0003]    Various patents have disclosed devices in which rubber is presently being transported and of the need not to use wooden pallets to transport rubber. Patents describing the devices are as follows: U.S. Pat. Nos. 5,613,447, 5,881,651, and 6,490,982 all having been issued to Howard J. Trickett. Mr. Trickett has also applied for U.S. application Ser. No. 11/828,972, presently pending and having been published on Jan. 31, 2008. None of the patents or applications disclose a tray sheet and slip system that provides a means for thawing the rubber being transported, that prevents the rubber being stacked together from being fused, and that does not damage the packaged rubber when a forklift&#39;s forks are inserted between two stacked bales using the present tray and slip sheet system. 
         [0004]    For the foregoing reasons, there is a need for a tray and slip sheet system for transporting rubber that will provide a means for thawing the rubber being transported, that prevents the large rubber bales being stacked together from being fused, and that does not damage the packaged rubber when a forklift&#39;s forks are inserted between two stacked rubber bales using the present tray and slip sheet system. 
       SUMMARY 
       [0005]    The present invention is directed to a tray and slip sheet system for transporting aggregated bales of rubber that provides a means for thawing the rubber being transported, that prevents the larger rubber bales being stacked together from being fused, and that does not damage the packaged rubber when a forklift&#39;s forks are inserted between two stacked rubber bales using the present tray and slip sheet system. 
         [0006]    The tray and slip sheet system comprises of a tray sheet, a slip, and securing system. The tray sheet has a foot print and four interconnecting flaps, each flap defines at least one rectangular ventilation slit and a securing mechanism. The tray sheet is used by placing the tray sheet on a flat surface and then placing a first layer of six bales within the footprint of the tray sheet. Up to six layers of bales can be stacked on the tray sheet. Each bale can weigh up to 35 kilograms and the tray sheet can support up to 2.52 metric tons. After the first two levels of bales are placed in the footprint, the flaps are raised and interconnected. Then the securing means, plastic straps, are threaded within apertures of each flap and then secured. When stacking the levels of rubber desired, usually a plastic film or wrap is placed between each level to prevent fusing and then the plastic film is wrapped around the exterior of the stacked bales to provide stability, thereby forming an aggregated bale. And when stacking aggregated bales, then placing a slip having a slip footprint and a slip flap on a bale aggregation so that the slip footprint is placed on the top of the bottom bale aggregation, then folding the slip flap over the side of the bottom aggregated bale, and then securing the slip flap with a slip securing strap. 
         [0007]    An object of the present invention is to provide a tray and slip sheet system that will allow rubber being transported to thaw. 
         [0008]    Another object of the present invention is to prevent the larger rubber bales being stacked together from being fused. 
         [0009]    Yet, another object of the present invention is to maximize the space within a container when stacking aggregated bales within the container. 
         [0010]    Still, another object of the present invention is to maximize the space in a warehouse when the system is not in use. For example, 180 tray sheets occupy the same space as one wooden pallet. 
         [0011]    A further object of the present invention is to eliminate the need of the use of wooden or plastic pallets when transporting bales of rubber. 
         [0012]    Yet, a further object of the present invention is to reduce the total weight of containers using the present invention. 
         [0013]    Still, a further object of the present invention is to provide a rubber bale carrying system that is recyclable. 
         [0014]    Yet still a further object of the tray and slip sheet system is to provide a system that defines an air recirculation system that allows the first two levels of bales stacked over the footprint to be defrosted in hot air chambers after winter transport. Systems not having ventilation slits do not allow the first two levels of bales being transported from being completely defrosted. This causes problems when using the rubber to produce end products, e.g., if producing tires, the tires produced will not have the same consistency. 
     
    
     
       DRAWINGS 
         [0015]    These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and drawings where: 
           [0016]      FIG. 1  shows a perspective view of a tray and slip sheet system having six levels of bales stacked within each tray and slip sheet system, the figure shows how the forks from a fork lift would slide between each system when lifting an upper tray and slip sheet system; 
           [0017]      FIG. 2  shows a perspective view of how a composite (each bale is not shown) of six bales would be placed on the footprint of the tray sheet; 
           [0018]      FIG. 3  shows a perspective view of the tray and slip sheet system, wherein the flaps of tray sheet are interconnected, six levels of bales are on the footprint of the tray sheet, and how at least one slip would be placed on the top level of bales placed on the tray sheet; 
           [0019]      FIG. 4  shows a perspective view of how one tray and slip sheet system would be stacked upon another; 
           [0020]      FIG. 5  shows a top plan view of the slip that would be placed on top of the top level of bales placed on each tray sheet; and 
           [0021]      FIG. 6  shows a top plan view of the tray sheet. 
       
    
    
     DESCRIPTION 
       [0022]    As seen in  FIGS. 1-3 , a tray and slip sheet system  100  for transporting aggregated bales of rubber, comprises, as seen in  FIGS. 2 and 6 , a tray sheet  200 , the tray sheet  200  having a footprint, two opposing long tray sheet flaps, and two opposing short tray sheet flaps, the tray sheet foot print  210  defines at least one rectangular ventilation slit  212 , each of the tray sheet flaps  220  define at least one rectangular ventilation slit  222  and at least a pair of strap apertures  224  in which a securing means  240  could be threaded through, each of the long tray sheet flaps defines a set of female receiving means at each opposite end of each long tray sheet flap and each of the short tray sheet flaps defines a set of male appendages at each opposite end of each short tray sheet so that when the tray sheet flaps are folded in a perpendicular position from the footprint, each set of appendages slides into each set of vertical female receiving apertures. In a preferred embodiment of the present invention, each tray sheet flap  220  might have at least three levels of strap apertures  224  and each level would have at least two pairs of strap apertures  224 , the strap apertures  224  would be positioned at a same position within each level. As seen in  FIG. 1 , the tray and slip sheet system  100  of the present invention, further comprises of at least one tray sheet strap  240 , the tray sheet strap  240  might be made of rubber, and is threaded within each strap aperture  224  of each tray sheet flap  220  and then secured together. As seen in  FIGS. 3 and 5 , the present invention further might comprise of at least one slip  300 , each slip  300  having a slip footprint  310  and a slip flap  320 , the slip foot print  310  defines at least one rectangular ventilation slit  312 , each slip flap  320  further defines at least one rectangular ventilation slit  322  and at least one pair of slip strap apertures  324 , and a slip strap  330 , the slip strap  330  is threaded through the pair of slip strap apertures  324  and is connected after the slip  300  is placed over an aggregation of bales of rubber after the aggregation of bales of rubber have been placed and secured over the footprint  210  of the sheet tray  200 . 
         [0023]    In a preferred embodiment of the preferred invention, the tray and slip sheet system  100  has a length of 80.75 inches and a width of 68.50 inches and a height of 1.00 millimeter. The footprint  210  of the tray sheet  200  has a length that is 52.75 inches and a width of 40.50 inches. The slip  300  has a length of 20 inches, a width of 15 inches, and a height of 1.00 millimeter. The footprint  310  of the slip  300  has a length of 13.00 inches and a width of 15.00 inches, while the slip flap  320  has a length of 7.00 inches and a width of 15.00 inches. 
         [0024]    All of the rectangular ventilation slits  212 / 222 / 312 / 322  of the present invention define apertures measuring at least 0.50 of an inch width and at least 5.00 inches in length. The ventilation slits  212 / 222 / 312 / 322  are needed to allow the rubber being transported to breath during the thaw process. The ventilation slits  212 / 222 / 312 / 322  are positioned throughout the sheet tray  200  and slip  300  to maximize the amount of ventilation that could contact the aggregated rubber bale without compromising the tray sheets  200  carrying capacity. 
         [0025]    In a preferred embodiment, the tray sheet&#39;s  200  rectangular ventilation slits  210 / 222  measure 0.50 of an inch in width and are 5.00 inches in length. The tray sheet footprint  210  defines six rectangular ventilation slits  212 . The tray sheet flaps  220  define sixty-four rectangular ventilation slits  222 , the slits  222  are positioned so that each long tray sheet flap  250  defines twenty-two rectangular ventilation slits  222  and each short tray sheet flap  260  defines ten rectangular ventilation slits  222 . The slip&#39;s rectangular ventilation slits  322  measure 0.75 of an inch in width and measure 5.00 inches in length, wherein the slip footprint  310  defines four rectangular ventilation slits  312  and the slip flap  320  defines two rectangular ventilation slits  322 . 
         [0026]    In another embodiment of the present invention, the long tray sheet flaps  250  have a width of 14 inches, the short sides  250   a  of the long tray sheet flaps  250 , and have a length of 52.75 inches, the long side  250   b  of the long tray sheet flap  250 . There are two opposing long tray sheet flaps  250 . Each long tray sheet flap  250  has 3 sets of 6 slip strap apertures  224 . The sets  224  are distributed within each long tray sheet flap  250  so that a first set of slip strap apertures  224  is adjacent to one of the short sides  250   a  of the long tray sheet flaps  250 , a second set  224  is parallel to the first set of slip strap apertures  224  and is centrally located on the long tray sheet flap  250 , and a third set of slip strap apertures  224  is adjacent to the other short side  250   a  of the long tray sheet flap  250 . Each long tray sheet flap  250  has 3 sets of 6 rectangular ventilation slits  222 . The sets are distributed within each long tray sheet flap  250  so that the first set of rectangular ventilation slits  222  are adjacent to the long side  250   b  of the long tray sheet flat, the second set of the rectangular ventilation slits  222  are parallel to first set of the rectangular ventilation slits  222  and are centrally located within the long tray sheet flap  250 , and the third set of rectangular ventilation slits  222  are parallel to the second set of rectangular ventilation slits  222  and are adjacent to the footprint  210 . Each long tray sheet flap  250  defines an additional two sets of two rectangular apertures  222  that run adjacent to the short sides  250   a  of the long tray sheet flaps  250 . 
         [0027]    The short tray sheet flaps  260  have a width of 14 inches, the short sides  260   a  of the short tray sheet flaps  260 , and a length of 40.5 inches, the long sides  260   b  of the short tray sheet flaps  260 . There are two opposing short tray sheet flaps  260 . Each short tray sheet flap  260  has 2 sets of 6 slip strap apertures  224 . The sets  224  are distributed within each short tray sheet flap  260  so that a first set of slip strap apertures  224  is approximately 9.5 inches from one of the short sides  260   a  of the short tray sheet flap  260  and the second set of slip strap aperture  224  is approximately 9.5 from the other side of the short side  260   a  of the short tray sheet flap  260 . Each short tray sheet flap  260  has six staggered rectangular ventilation slits  222  centrally located within the short tray sheet flap  260  and two sets of two rectangular ventilation slits  222 , each set of two rectangular ventilation slits  222  runs adjacent to each short side  260   b  of the short tray sheet flap  260 . 
         [0028]    Note, each rubber bale is placed on the tray sheet footprint  200  weighs thirty-five kilograms and is positioned so that three bales of rubber shall be positioned side by side in the tray sheet along the length of the footprint and a second set of three bales of rubber shall be placed immediately behind the initial three bales of rubber so that a 3 by 2 pattern emerges within each level of rubber stacked within the footprint. Each tray sheet footprint  200  can support six levels of rubber bales once the flaps of the tray sheet are secured in place. The flaps will cover the first two levels of bales stacked. 
         [0029]    As seen in  FIG. 1 , in practice, after at least the first two levels of bales are placed in the tray sheet footprint  200 , the flaps  220  are raised and interconnected. Then the securing means  240 , plastic straps, are threaded within apertures  224  of each flap  220  and then secured. After stacking the levels of rubber desired, usually a plastic film or wrap is wrapped around the bales to prevent impurities from contaminating the rubber and thereby forming an aggregation of bales of rubber. 
         [0030]    When stacking aggregated bales of rubber using the present invention, the slip&#39;s  300  footprint  310  is placed on the top of the bottom bale aggregation being stacked, the slip flap  320  is folded over the side of the aggregated bale and then is secured by the slip strap  330 . 
         [0031]    The tray sheet and slip of the present invention might be made of HDPE, high density polyethylene. Yet, the system may be made of any other recycled rubber having an ethylene composition. 
         [0032]    An advantage of the present invention is that it provides a tray and slip sheet system that allows rubber transported to thaw. 
         [0033]    Another advantage of the present invention is that it prevents stacked aggregations of rubber bales from fusing together. 
         [0034]    Yet, another advantage of the present invention is that it maximizes the space within a container when stacking aggregated bales within the container. 
         [0035]    Still, another advantage of the present invention is that it maximizes the space in a warehouse when the system is not in use. 
         [0036]    A further advantage of the present invention is that it eliminates the need of the use of wooden or rubber pallets when bales of rubber are transported. 
         [0037]    Yet, a further advantage of the present invention is that it reduces the total weight of containers using the present invention. 
         [0038]    Still, a further advantage of the present invention is that it provides a rubber bale carrying system that is recyclable. 
         [0039]    Yet further advantage of the tray and slip sheet system is that it provides a system that defines an air recirculation system that allows the first two levels of bales stacked over the footprint to be defrosted in hot air chambers after winter transport. Systems not having ventilation slits do not allow the first two levels of bales being transported from being completely defrosted. 
         [0040]    Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore the spirit and the scope of the claims should not be limited to the description of the preferred versions contained herein.