Abstract:
A skeletal substrate associated with a composite over spray or over molded article, such as a stackable pallet. The skeletal substrate includes a three dimensional article, such as a durable corrugated paperboard or other material, with a load supporting and planar upper surface and a recess configured and pallet fork receiving underside. The substrate incorporates a repeating pattern of cylindrical, polygonal, wave like or other shapes, such as which are coated in built up fashion with a polymeric material in order to provide insulating of the substrate from the environment as well as to provide additional strength.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 12/467,601, filed May 18, 2009 (pending), which claims the benefit of U.S. provisional patent application Ser. No. 61/074,306, filed Jun. 20, 2008 (now abandoned), and which is a continuation-in-part of U.S. patent application Ser. No. 12/414,017, filed on Mar. 30, 2009 (pending), which claims the benefit of U.S. provisional patent application Ser. No. 61/040,228 filed Mar. 28, 2008 (now abandoned). 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to a composite stackable construction for providing heavy duty platform support. More particularly, the present invention teaches a skeletal substrate associated with a composite over spray or over molded article, such as a stackable pallet. The skeletal substrate includes a three dimensional article, such as a durable corrugated paperboard or other material, with a load supporting and planar upper surface and a recess configured and pallet fork receiving underside. The substrate incorporates a repeating pattern of cylindrical, polygonal, wave like or other shapes, such as which are coated in built up fashion with a polymeric material in order to provide insulating of the substrate from the environment as well as to provide additional strength. 
       BACKGROUND OF THE INVENTION 
       [0003]    Transport and support pallet assemblies are known in the relevant art and which are provided for supporting varying sized loads during storage or transport. Such pallet assemblies can include such as wooden or plastic construction and can further exhibit multi-piece construction. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention discloses a structurally reinforcing and three dimensional article, such as a pallet, having a structurally supporting skeletal substrate. The skeletal substrate includes a three dimensional article, such as a durable corrugated paperboard or other material including a galvanized steel exhibiting a rigid and structurally supporting construction and with a load supporting and planar upper surface and a recess configured and pallet fork receiving underside. 
         [0005]    The substrate incorporates a repeating pattern of cylindrical, polygonal, wave like or other shapes, such as which are coated in built up fashion with a polymeric material in order to provide insulating of the substrate from the environment as well as to provide additional strength. A composite plasticized material is over-molded or otherwise applied upon the structural insert according to a selected thickness to encapsulate the insert. The composite material can further include any of a heat/fire thermosetting or a thermoplastic material. Additional variants contemplate an aggregate material entrained or otherwise mixed within the plasticized material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: 
           [0007]      FIG. 1  is a perspective view hi partial cutaway of a structural supporting skeletal substrate incorporated into a polymeric built up and load support pallet and exhibiting a plurality of vertically extending tubular portions according to a first pattern; 
           [0008]      FIG. 2  is a succeeding perspective view of a further slightly modified substrate exhibiting a plurality of horizontally extending tubular portions; 
           [0009]      FIG. 3  is an enlarged sectional cutout view of the tubular portions as exemplary shown in the variant of  FIG. 1  and exhibiting a first specified individual wall thickness; 
           [0010]      FIG. 4  is a sectional view of a plurality of tubular portions exhibiting a second and lesser specified wall thickness; 
           [0011]      FIG. 5  is an enlarged sectional of the tubular portions shown in  FIG. 4 ; 
           [0012]      FIG. 6  is a modified sectional view of a further plurality of thin walled tubular portions combined with an interconnecting and crosswise extending wall grid pattern for achieving additional structural support; 
           [0013]      FIG. 7  is a further sectional illustration of a plurality of tubular portions exhibiting individual concentric patterns; 
           [0014]      FIG. 8  is an illustration of a plurality of undulating or wave-like interconnected portions according to a further substrate pattern; 
           [0015]      FIG. 9  is an illustration of a pseudo honeycomb pattern exhibited by a plurality of hexagonal cross sectional shaped portions; 
           [0016]      FIG. 10  is an enlarged side illustration of area  10 - 10  in  FIG. 2  and illustrating the horizontal extending arrangement of the tubular portions; 
           [0017]      FIG. 11  is a view similar to  FIG. 10  of a first selected modified structure and illustrating a first upper row of tubular portions and a second lower and crosswise extending row of tubular portions encased within an outer frame of the skeletal substrate; 
           [0018]      FIG. 12  is a further modification to that show in  FIG. 11  and by which a central row of tubular portions is separated by upper and lower half tubular portions; 
           [0019]      FIG. 13  is a further variation in which a single horizontally extending row of tubular portions of enlarged diameter are incorporated within the outer substrate frame; 
           [0020]      FIG. 14  is a further variation of a single row of modified elongated and open ended tubular portions each adopting a generally “U” shape; 
           [0021]      FIG. 15  is an illustration similar to  FIG. 11  and depicting upper and lower parallel extending rows of tubular portions; 
           [0022]      FIG. 16  is an illustration similar to  FIG. 12  and depicting first, second and third horizontally extending and vertically spaced rows of tubular portions in alternating crosswise extending fashion; 
           [0023]      FIG. 17  is a slight modification of the illustration of  FIG. 12  and by which the intermediate extending row of tubular portions are segmented; and 
           [0024]      FIG. 18  is a further modification of a plurality of elongate portions each including upper and lower tubular components separated by parallel and spaced structural supporting walls. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    Referring now to the following illustrations, a series of perspective and sectional/cutaway views are shown of a variety of structural supporting inserts such as which are incorporated into selected composite stackable pallet construction. As previously described, the stackable pallet construction is designed so as to provide heavy duty support of items located thereupon and exhibits, according to the selected variant, a structural spine or insert (such as a heavy duty paperboard corrugated material or galvanized insert) which operates to greatly enhance the strength of the pallet assembly in supporting heavier loads set thereupon. 
         [0026]    As will be further described in detail, the mariner of constructing the structural pallet article is such that the inner structural supporting insert is placed within a mold cavity, or other manufacturing medium associated with the creation of the pallet article, and about which is injection molded or otherwise formed a fire/heat proof composite thermoset or composite thermoplastic material. As will be further described, the completed pallet article can be solid, however can also encompass interiorly extending open apertured locations, recesses or other configurations, these further reducing the overall weight of the pallet without compromising its strength. The underside of each pallet can further exhibit linear width and/or length extending recesses, and which are designed to seat inserting forks associated with a conventional forklift machine. 
         [0027]    Referring now to  FIG. 1 , a perspective view is generally shown at  10  in partial cutaway of a structural supporting skeletal substrate according to one non-limiting embodiment. The substrate as shown exhibits a generally planar and three dimensional shape with a top exhibiting a planar surface  12 , a plurality of four interconnected sides  14 ,  16 ,  18  and  20  and a generally hidden underside defining a generally square or rectangular shape. Also shown are a plurality of recessed and underside accessible surfaces, see at  22  and  24  associated with side  14  and further at  26  and  28  with interconnected side  16 , and which are incorporated into the substrate construction in order to receive forward inserting forks (not shown) associated with a pallet lift vehicle or the like. 
         [0028]    As previously indicated, the layers  12 - 20  defining the skeletal support or substrate insert are constructed of any of a number of materials, but according to non-limiting and preferred embodiments can include such as a pretreated and heavy duty corrugated paperboard or a galvanized and lightweight metal. As further shown in  FIG. 1 , a plurality of vertically extending tubular or cylindrical sleeve shaped portions are illustrated in removed cutaway, at  30 , and which are sized and arranged in side-by-side aligned fashion so as to vertically extend fashion a specified height corresponding generally to an overall height of the substrate  10 . 
         [0029]    The portions  30  are, in one variant, constructed of a similar corrugated paperboard or galvanized material, however are also envisioned to include other materials. As further shown in  FIG. 3 , an enlarged sectional cutout view of the tubular portions  30  is again illustrated and exhibiting a first specified individual wall thickness corresponding to the desired structural performance requirements of the substrate. 
         [0030]    In use, the sleeve portions  30  provide structural support to the substrate and can, in one application, be both environmentally pre-treated (such as by application of water and mildew resistant sprays or coatings) prior to being encased within the outer assembled top  12 , sides  14 - 20  and bottom of the structure and in order to provide increased levels of structural and load bearing support. Alternatively, the cylindrical portions  30  can remain accessible through any arrangement of apertures or openings defined in the top, sides or bottom of the substrate. 
         [0031]    As further shown, a subsequently applied polymeric material (see as further representatively illustrated by polymeric built-up portion  32  which can be provided to any thickness and which can include either or both of a spray on plastic or a dipped/molten flowing material) can coat or build up either the exterior surfaces of the substrate. Although not shown, it is also understood that the polymeric applied material can incorporate or entrain an aggregate or other suitable additive in order to enhance its performance characteristics. 
         [0032]    Alternatively, and depending upon any particular apertured configuration imparted into the surfaces of the substrate in combination with the particular manufacturing process employed, the polymeric flowable or sprayed material can also flow into the interior of the substrate where the portions  30  are located in order to coat and seat about them according to a desired thickness. In each of the disclosed variants, and in particular where the substrate material is a corrugated paperboard, it is desirable to maintain the integrity of the material from the effects or environmental moisture and contaminants, this tending to degrade both its physical properties and load supporting characteristics. 
         [0033]    Referring now to  FIG. 2 , a succeeding perspective view is shown at  34  of a further slightly modified substrate from that shown in  FIG. 1  and which exhibits a pluralities of horizontally (lengthwise) extending tubular portions defied within the three dimensional structural substrate, these including a first extending central row  36  and each of parallel upper  38  and lower  40  half-pipe rows. A partial illustration is further shown in  FIG. 10  of an enlarged side illustration of area  10 - 10  in  FIG. 2  and illustrating the horizontal extending arrangement of the tubular portions  36 ,  38  and  40 , such as extending between top  12 , side  14  and a bottom-most location  25  intended to designate a location of maximum thickness of the pallet construction. 
         [0034]    As previously indicated, the overall shape of the substrate, as defined by the top  12 , sides  14 - 20  and bottom surfaces, is consistently illustrated throughout the several views depicted herein, such that the same reference numerals are repeated throughout (with reference also to  FIGS. 11-18 ) for purposes of ease of explanation. That said, the present invention also contemplates the use of any outer defined shape associated with the structural supporting substrate, this including panel shaped or otherwise. 
         [0035]    As further shown, the side  16  illustrated in  FIG. 1  is removed in  FIGS. 2 and 10 , such as to illustrate the manner in which the designated rows of cylindrical portions  36 ,  38  and  40  horizontally extend. Alternatively, it is envisioned that one or more sides of the substrate (such as again referenced at  14 ,  16 ,  18  and  20 ) can be removed in order to facilitate a polymeric built-up coating within the inner defined surfaces of each portion  36 ,  38 ,  40  as well as separated areas between each portion (see further at  42 ). 
         [0036]    In comparison to  FIG. 3 ,  FIG. 4  is a further sectional view  44  of a plurality of tubular portions  46 , each exhibiting a second and lesser specified wall thickness than which is associated with the portions  30  referenced in the variant of  FIGS. 1 and 3 .  FIG. 5  is an enlarged sectional of the tubular portions shown in  FIG. 4 , with  FIG. 6  further exhibiting a modified sectional view, at  48 , of a further plurality of even thinner walled tubular portions  50  combined with an interconnecting and crosswise extending wall grid pattern, see at  52 , which intersects the vertically extending portions for achieving additional structural support. The grids  52 , although shown in top cutaway, can extend either partially or entirely the distance between the top  12  and bottom  25  surfaces of the substrate corresponding to the maximum height of the substrate. 
         [0037]    Referring now to  FIG. 7 , a further sectional illustration is shown at  54  of a plurality of tubular portions  56 , each of which individually exhibits an additional and inner concentric pattern, see inner portions  58 . Although not shown, each individual outer tubular portion  56  and inner coaxial portion  58  can be individually sealed. Alternatively, and consistent with the previous description, outer layers of the substrate can be open at locations to coat the exterior of the portions, these further potentially including additional apertured or slotted locations to facilitate inner flow of polymeric material to assist in coating the inner portions  58 . 
         [0038]    Referring to  FIG. 8 , an illustration is shown at  60  of a plurality of undulating or wave-like interconnected portions, see at  62 ,  64 , in sequential and repeating fashion, this according to a further substrate pattern.  FIG. 9  is an illustration at  66  of a further plurality of interior structural supporting portions pseudo honeycomb pattern, see individual and adjoining edge portions  68 ,  70 ,  72 , et seq., each of which exhibits a hexagonal cross sectional shaped portions. 
         [0039]    Proceeding to  FIG. 11 , a view similar to  FIG. 10  is shown at  74  of a first selected modified structure and illustrating a first upper row of tubular portions (shown by representative portion  76 ) and a second lower and crosswise extending row of tubular portions, see further as defined by tubular walls  78 , again encased within the outer frame of the skeletal substrate.  FIG. 12  is a further modification to that show in  FIG. 11 , at  80 , and by which a central row of tubular portions, at  82 , is separated by upper  84  and lower  86  (reduced length) half tubular portions. 
         [0040]      FIG. 13  is a yet further variation  88  in which a single horizontally extending row of tubular portions  90  of enlarged diameter are incorporated within the outer substrate frame (again representatively shown by top  12 , side  14  and bottom most surface  25  and inwardly stepped recessed surface  26 .  FIG. 14  is a further variation, at  92 , of a single row of modified elongated and open ended tubular portions each adopting a generally “U” shape with a curved base  94  and interconnected sides  96  and  98  which are arranged relative to the top  12  and bottom  25  surfaces in aligning and alternating direction. As further shown, the dimension of the open ended tubular portions decreases, see as further shown at  100  at a location corresponding to the arrangement of the recessed underside  26 . 
         [0041]      FIG. 15  is an illustration  102  similar to  FIG. 11  and depicting upper  104  and lower  106  parallel extending rows of tubular portions.  FIG. 16  is an illustration  108  similar to  FIG. 12  and depicting first  110 , second  112  and third  114  horizontally extending and vertically spaced rows of tubular portions in alternating crosswise extending fashion.  FIG. 17  is a slight modification  116  of the illustration of  FIG. 12  and by which the intermediate extending row of tubular portions are segmented, at  118 ,  118 ′,  118 ″ et seq. 
         [0042]    Finally,  FIG. 18  is a further modification  120  of the structural substrate and in which a plurality of elongate portions are provided. The elongate portions as illustrated each include upper  122  and lower tubular  124  components separated by parallel and spaced structural supporting walls  126  and  128  and are arranged in aligning and overlapping fashion as shown. 
         [0043]    The structural substrate can exhibit, without limitation, any desired length, width, height/thickness dimension. It is also envisioned and understood that the construction and arrangement of the interior structural supporting portions are not limited to those illustrated and that further structural deeming interior patterns or structure beyond those shown are also envisioned. 
         [0044]    Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.