Abstract:
A transport item of a body of foamed thermoset material is described having a density that varies across the thickness of the body with the greatest density being proximate an outer surface of the body.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 13/290,601, filed Nov. 7, 2011, which claims the benefit of U.S. Provisional Application No. 61/411,501, filed Nov. 9, 2010, the contents of which are incorporated herein by reference. 
    
    
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     FIELD OF THE INVENTION 
     The present invention generally relates to an improved top frame, pallet support board, pallet, dolly, insulated tote, and other related transport items, and a material and process for making the same. The present invention also relates to an insertable component such as a grommet, caster, latch, gasket, or other component formed in such items. 
     BACKGROUND OF THE INVENTION 
     Plastic pallets have long been used to transport and store goods and other materials. Plastic top frames have been used with the plastic pallets to secure a load of goods or materials to the pallet. The frames allow for placement of bands or straps around the pallet and goods to prevent the load from slipping on or falling off the pallet. 
     The load is placed on the pallet, and the top frame is placed on top of the load. The load is then secured to the pallet by wrapping straps or banding around the pallet, the load, and the top frame. The banding can be plastic, metal or other suitable material. The top frame can also facilitate stacking of pallets during transport or storage. 
     Additionally, plastic pallet support boards have been used to allow pallets of different sizes to be more easily handled. For example, a warehousing operation may employ different sized pallets to move or store goods or materials. The different sized pallets are placed on pallet support boards to facilitate handling in a more standardized manner. Some users place goods or materials directly on the pallet support boards. Known plastic pallets can be heavy. Known plastic pallets, pallet support boards, and top frames are also more expensive than their wooden counterparts. 
     Plastic dollies are used to move materials from one place to another. Plastic dollies have casters to allow loads to be placed upon the dolly and more easily move the load from place to place. Known dollies are made from a thermoplastic material, and are roto-molded, making them hollow. Dollies made this way are subject to breakage due to use and abuse. These dollies are also heavy and expensive to manufacture. 
     Totes are currently sometimes used to carry materials requiring temperature control. This requires the materials to be placed in insulated bags, and the bags placed inside the totes. Also, closed cell extruded polystyrene foam (Styrofoam) containers are sometimes used as are steam chest molded containers. Items are placed in the Styrofoam containers, which are then placed inside the totes. Styrofoam containers do not stand up to repeated use. Also it is difficult to wash such containers leading to potential biohazards. 
     Many of the prior transportation and storage components used in the industry have one or more problems. Some are formed with expensive and/or heavy materials, such as thermoplastic. Others are formed from wood or fiberboard, which can crack or rot. Some use multiple extruded pieces which require additional assembly and risk becoming loose (e.g., a top frame formed from extruded top frame arms connected by corner pieces). Others have hollow portions that can become contaminated if cracked. 
     Thermoset plastic pallets, dollies, totes, top frames, and pallet support boards can have outer surfaces with a low coefficient of friction. The low coefficient of friction for such surfaces can cause items placed on the surfaces to slide or shift. The low coefficient of friction also can cause stacked pallets, top frames, dollies, totes, and pallet support boards to slide or shift with respect to each other. The present invention is an improvement on all of these as it eliminates or significantly reduces the sliding and shifting by increasing the coefficient of friction of the outer surfaces, thus allowing the product to be used in traditional material handling environments such as with forklifts, palletizers, and conveyors. 
     SUMMARY OF THE INVENTION 
     The present invention relates to an improved pallet, top frame, pallet support board, dolly, insulated tote, and other similar items formed from a thermoset foam material. The thermoset foam material provides sufficient strength characteristics while being lightweight and easy to handle. 
     In one embodiment, a top frame made from a thermoset foam material is provided. The top frame includes a pair of substantially parallel sides and a pair of substantially parallel ends connected to the sides to form a generally rectangular frame structure. The frame structure has an inner layer and an outer surface. The frame structure also has a thickness. The top frame is made from a thermoset foam material. The thermoset foam material varies in density along the frame structure thickness such that the density of the thermoset foam material is greatest nearest the outer surface to form a hard outer shell. 
     In another embodiment, the top frame for use in combination with a transport item, such as a pallet, carrying goods is provided. The top frame includes a unitary frame formed from a thermoplastic foam having an interior foam portion and an exterior surface foam portion. The interior foam portion has a first foam density. The exterior surface foam portion has a second foam density greater than the first foam density. The exterior foam portion forms a hard skin surrounding the interior foam portion. 
     In another embodiment, a pallet support board made from a thermoset foam material is provided. The pallet support board includes a generally rectangular deck having an inner layer and an outer surface defining a thickness. Again, the thermoset foam material varies in density along the pallet support board thickness such that the density of the thermoset foam material is greatest near the pallet support board outer surface to form a hard outer shell. 
     In a further embodiment, a pallet made from a thermoset foam material is provided. The pallet includes a deck having an inner layer and an outer surface defining a thickness. Similar to the top frame and pallet support board, the thermoset foam material varies in density along the pallet thickness such that the density of the thermoset foam material is greatest near the pallet outer surface to form a hard outer shell. In other embodiments, the top frame, pallet support board, and pallet include a substrate coated with a polyurea material. 
     In another embodiment a tote made from a thermoset foam material is provided. The tote includes a pair of opposing side walls and a pair of opposing end walls. It also includes a lid having a first side and a second side. The tote includes a liner. The liner is sized and shaped to be inserted into the tote. The tote also includes a cover to be placed on top of the liner, and still allow the lid to completely close. The lid can be attached to the tote in other suitable ways, such as hinges. 
     In a further embodiment a dolly made from a thermoset foam material is provided. The dolly has includes a body. The body includes a caster at each corner. The body includes an elevated edge and an opening in its center. 
     In a still further embodiment, the present invention provides a top frame. The top frame has first and second substantially parallel sides, and first and second substantially parallel ends connected to the first and second sides to form a generally rectangular frame structure with a central opening. The frame structure has an inner layer and an outer surface, and a thickness. The top frame is made from a thermoset foam material, the thermoset foam material varying in density along the frame structure thickness such that the density of the thermoset foam material is greatest nearest the outer surface to form a hard outer shell. 
     The pallet support board, top frame, pallet, tote, and dolly can be made of a “self-skinning” foam. Alternatively, such items may also have a generally uniform density throughout their thickness. Additionally, insertable components such as grommets, reinforcements, hinges, casters, gaskets may be similarly formed in the pallet support board, pallet, tote, and dolly. 
     Thermoset foam is lighter and less expensive than its plastic counterparts in the manufacture of pallets, top frames, or pallet support boards and other related components. Moreover, thermoset materials do not have the memory or “creep” inherent in thermoplastics, rather the material keeps its shape when heated and over extended use. Additionally, such items made according to the present invention are made of a single piece. 
     In a further embodiment, the present invention provides a transport item for shipping goods. The transport item includes a body having first outer surface and a second outer surface, and a thickness therebetween. The body is formed from a thermoset foam material. The transport item also includes a first insertable component having a first portion located within the thickness of the body and a second portion that extends outside of the body beyond the first outer surface. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following Figures. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       To understand the present invention, it will now be described by way of example, with reference to the accompanying Figures in which: 
         FIG. 1  is a top perspective view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 2  is a side plan view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 3  is an end plan view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 4  is a top plan view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 4A  is a top perspective view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 5  is a top perspective view of a top frame in accord with an embodiment of the present invention. 
         FIG. 6  is a side plan view of a top frame in accord with an embodiment of the present invention. 
         FIG. 7  is an end plan view of a top frame in accord with an embodiment of the present invention. 
         FIG. 8  is a top plan view of a top frame in accord with an embodiment of the present invention. 
         FIG. 8A  is a top perspective view of a top frame in accord with an embodiment of the present invention. 
         FIG. 9  is a top perspective view of a pallet in accord with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional view of a reinforcement in accord with an embodiment of the present invention. 
         FIG. 11  is a cross-sectional view of a reinforcement in accord with an embodiment of the present invention 
         FIG. 12  is a cross-sectional view of a reinforcement in accord with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional view of a reinforcement in accord with an embodiment of the present invention. 
         FIG. 14  is a perspective cross-sectional view of a top frame in accord with an embodiment of the present invention. 
         FIG. 15  is a schematic view showing the process for making self-skinning foam in accord with an embodiment of the present invention. 
         FIG. 16  is a plan view of a dolly in accord with an embodiment of the present invention. 
         FIG. 17  is a side view of a dolly in accord with an embodiment of the present invention. 
         FIG. 18  is a perspective view of an insulated tote in accord with an embodiment of the present invention. 
         FIG. 19  is a perspective view of an insulated tote in accord with an embodiment of the present invention. 
         FIG. 20  is a cross-sectional perspective view of an insulated tote in accord with an embodiment of the present invention. 
         FIG. 21  is a perspective view of a dolly in accord with an embodiment of the present invention. 
         FIG. 22  is a perspective view of an insulated tote in accord with an embodiment of the present invention. 
         FIG. 23  is a perspective view of an insulated tote in accord with an embodiment of the present invention. 
         FIG. 24  is a perspective view of a top frame in accord with an embodiment of the present invention. 
         FIG. 25  is an enlarged sectional view of a top frame grommet in accord with an embodiment of the present invention. 
         FIG. 26  is perspective view of a mold for a top frame in accord with an embodiment of the present invention. 
         FIG. 27  is a perspective view of a top frame within a mold in accord with an embodiment of the present invention. 
         FIG. 28  is a perspective view of a bottom portion of a mold in accord with an embodiment of the present invention. 
         FIG. 29  is a perspective view of a bottom portion of a mold with grommets in accord with an embodiment of the present invention. 
         FIG. 30  is a perspective view of a top portion of a mold in accord with an embodiment of the present invention. 
         FIG. 31  is a perspective view of a grommet in accord with an embodiment of the present invention. 
         FIG. 32  is a front view a grommet taken along plane A of  FIG. 31 . 
         FIG. 33  is a top view of a grommet taken along plane B of  FIG. 31 . 
         FIG. 34  is a perspective view of a tote in accord with an embodiment of the present invention. 
         FIG. 35  is a top view of a tote in accord with an embodiment of the present invention. 
         FIG. 36  is a bottom view of a tote in accord with an embodiment of the present invention. 
         FIG. 37  is a top view of a tote without the lid in accord with an embodiment of the present invention. 
         FIG. 38  is a bottom view of a tote lid in accord with an embodiment of the present invention. 
         FIG. 39  is a perspective view of a pallet support board in accord with an embodiment of the present invention. 
         FIG. 40  is a side sectional view of a pallet board with a gripper insert in accord with an embodiment of the present invention. 
         FIG. 41  is a perspective sectional view of a pallet board with a gripper insert in accord with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the Figures, and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, and is not intended to limit the broad aspect of the invention to the embodiments illustrated. 
       FIGS. 1 through 4A  show a pallet support board  10  made in accord with an embodiment of the present invention. The pallet support board  10  is made from a thermoset foam material. Suitable thermoset foam materials can include polyurethane foam, urethane foam, epoxy foam, phenolic foam, syntactic foam, polyaspartic foam, and hybrids of these foams. In a preferred embodiment, polyurethane foam is used. The pallet support board  10  includes a generally rectangular deck  12  having an inner layer  13  and an outer surface  15 . The inner layer  13  and outer surface  15  define a thickness  18 . A typical thickness  18  is on the order of ¼ to 1½ inches, however, the deck  12  can be of any suitable thickness for its intended application. The deck  12  also includes a pair of opposing ends  20 , and a pair of opposing sides  22 . The pallet support board  10  can be made in any size suitable for its application. 
     In an embodiment, both of the opposing ends  20  and opposing sides  22  include tapered sections  24  along an outer edge  25 . It will be understood that the tapered sections  24  need not be on both the opposing ends  20  and opposing sides  22 . Furthermore, as shown in  FIG. 4A , the tapered sections  24  may extend substantially along the entire length of one or both of the opposing ends  20  and/or opposing sides  22 . 
     In one embodiment, the tapered sections  24  are tapered across the thickness  18  from an upper surface  14  and lower surface  16 . The tapered sections  24  are sized and located to accept forklift tines during handling and transport. The deck  12  also includes on at least one of the upper surface  14  or lower surface  16  banding slots  28  to accommodate bands used to secure the pallet support board  10  to an associated loaded pallet or other item placed on the board. In one embodiment, at least portions of the upper surface  14  and/or lower surface  16  of the pallet support board  10  have an exterior skin that is rubberized or texturized to help prevent slippage between the pallet support board  10  and the load with which it is used. The pallet support board  10  may include hand holds  26  which extend through at least part of the thickness  18 . 
     In an embodiment of the pallet support board  10 , the foam varies in density along the thickness  18  of the deck  12  such that the density is greater nearest the outer surface  15 , including upper and lower surfaces  14  and  16 , than in the center of the thickness  18 . The density can vary continuously across the thickness  18 , or there can be two or more discrete layers of similar density, e.g., an inner density and an outer (i.e., skin) density. The density of the foam material near the outer surface  15  such that the foam creates a hard outer shell. Such material may include a “self-skinning” foam further described below. The higher density foam at the outer surfaces provides impact resistance and deflection strength as well as a hard surface and a stiff structure. In other embodiments, the pallet support board  10  is a generally uniform density throughout the thickness  18 . 
     In a preferred polyurethane foam embodiment, the foam is created from mixing two components: isocyanate and polyol. The formulation of the components is determined by the desired characteristics of the finished foam. In a preferred embodiment, the foam has a density in the range of 6 to 27 pounds per cubic foot, and more preferably in a range between 8 and 18 pounds per cubic foot, with higher densities at the outer surface  15 , including upper and lower surfaces  14  and  16 . 
     To make a polyurethane foam pallet support board  10 , the isocyanate and polyol are mixed either mechanically or manually. The polyol is available from Burtin Polymer Laboratories of Cartersville, Ga. In an embodiment of the invention, fire retardant materials may be added into the foam mixture to enhance resistance to fire. Coloring agents can also be added to the foam mixture for any desired color. The mixture is injected or poured into a tool cavity, where it will remain until cured. The foam is preferably molded using either reactive injection molding (RIM) or resin transfer molding (RTM) processes, although any suitable molding process may be used, including manually mixing and pouring the mixture into a mold cavity. After the mixture is poured into the mold, it must cure for a specified time depending on the formulation of the components. After curing, the foam pallet support board is ejected from the tool cavity either mechanically or manually. 
     One embodiment of the process  600  by which the self-skinning urethane foam is made is shown in  FIG. 15 . The process  600  includes a first tank  602  containing isocyanate. A second tank  604  contains polyol. The materials from tanks  602  and  604  are directed to a meter  606 . The meter  606  measures the desired amounts of isocyanate and polyol and their flow rates. The polyol is preferably heated at the meter  606  by a heater  608  to a temperature of approximately 125 degrees Fahrenheit. Thermally activated foam is preferable to chemically activated foam. After metering, the polyol and isocyanate are combined and inserted into an aluminum mold  610 . 
     It has been found that a range of between 6 and 10 pound per cubic foot density foam, constrained by the mold  610  creates the desired density and strength of material and the self-skinning feature of the foam. This desired density of the molded foam is between ten and nineteen pounds per cubic feet. Other ranges can be used depending on the application. Additionally, it has been found that maintaining the temperature of the mold  610  to between 80 and 100 degrees Fahrenheit results in the skin forming with the desired results. The closer to 80 degrees, the thicker the outer skin. It is believed that these temperatures result in the urethane in the foam solidifying where the foam meets the mold  610 . It has also been found that keeping the temperature of the materials warmer than the mold  610  before the material is inserted into the mold  610  could be important to proper skin formation. The self-skinning can also be accomplished using a foam formulation that would provide such skinning. 
     The mold  610  interior surfaces may be textured using known means such as sandblasting or acid etching. This creates a corresponding texture  612  (see  FIG. 14 ) in the exterior surface of the outer skin of a product formed in the mold. 
     In addition, the mixture of polyol and isocyanate can have one or more fillers added to reduce the cost of manufacture. Suitable fillers include ceramic microballoons, recycled glass, calcium carbonate and wollastonite. Ceramic microballoons provide an additional advantage in that they are 20% lighter than the foam, and add strength to the foam. Additionally, differing formulations for the polyol and isocyanate formulations can provide differing outer skin thickness. 
     In operation, the process includes the steps of providing a desired formulation of iscoyanate and polyol. At least one of the isocyanate and polyol are heated to a temperature of between 80 and 125 degrees Fahrenheit. The iscoyanate and polyol are combined to form a foam solution. The foam solution is injected into the mold  610 . Alternatively, the isocyanate and polyol are injected separately and mixed within the mold  610 . The mold  610  is heated to a temperature of between eighty and one hundred degrees Fahrenheit, preferably nearer eighty degrees. After injection, the foam mixture expands to fill the mold  610 . The mixture is left to cure within the mold  610 . The mold  610  constricts the expansion of the foam mixture to increase its density to the desired density. After curing, the finished product is removed from the mold. 
     In another embodiment, the finished foam pallet support board  10  may be coated with a polyurea material coating. The polyurea coating will increase the deflection strength of the pallet support board  10 , as well as increase its impact resistance, surface toughness, and wear resistance. In addition, the polyurea coating can have a textured surface to meet any desired friction characteristics. In an embodiment of the invention, a substrate such as a low, medium, or high density fiber board, or plywood can be coated with polyurea foam. A contemplated polyurea coating that may be used is Line-X or Bullet-Liner, available from Burtin Polymer Laboratories of Cartersville, Ga. 
       FIGS. 5 through 8A and 14  show a top frame  100  formed from a structural thermoset foam material in accord with an embodiment of the present invention. The top frame  100  has a pair of substantially parallel sides or legs  102  and a pair of substantially parallel ends or legs  104 . The sides  102  and ends  104  are connected to form a generally rectangular unitary frame structure  106  having a central opening  107 . The frame structure  106  can be sized in accord with its intended use. The frame structure  106  has an inner layer  105  and outer surface  109 , including upper surface  108  and a lower surface  110 . The upper surface  108  and lower surface  110  are separated by foam having a thickness  112 . The thickness  112  typically is on the order of ¼ to 1½ inches, but may be any thickness suitable for its intended application. In an embodiment, the top frame  100  includes one or more bracing members extending between the sides  102  and/or ends  104  and/or corners. 
     At least one of the sides  102  or ends  104  includes a tapered section  114  along an outer edge. It will be understood that the tapered sections  114  need not be on both the sides  102  and ends  104 . Furthermore, as shown in  FIG. 8A , the tapered sections  114  may extend substantially along the entire length of the ends  104  and/or sides  102 . In one embodiment, the tapered sections  114  are tapered from both the upper surface  108  and lower surface  110 . The tapered sections  114  are sized and located to accept forklift tines during handling and transport. The frame structure  106  also includes banding slots  116  on at least one of its upper surface  108  or lower surface  110  to accommodate bands used to secure the top frame  100  to an associated pallet. 
     Suitable thermoset foam materials can include polyurethane foam, urethane foam, epoxy foam, phenolic foam, syntactic foam, polyaspartic foam, and hybrids of these foams. In a preferred embodiment, polyurethane foam is used. The polyurethane foam material is made in the same general process and with the same general characteristics as described above with respect to the pallet support board  10 . 
     In an embodiment, the frame  100  is formed such that the foam varies in density along the thickness  112  of the frame structure  106  to have a density greater nearest the outer surface  109 , including upper and lower surfaces  108  and  110 , than in the center of the thickness  112 . The density can vary continuously across the thickness  112 , or there can be two or more discrete layers of similar density, e.g., an inner density and an outer (i.e., skin) density. In other embodiments, the top frame  100  is a generally uniform density throughout the thickness  112 . The density of the foam material near the outer surface  109 , and upper and lower surfaces  108  and  110  are such that the foam creates a hard outer shell. Such material may include a “self-skinning” foam as described above. A frame  100  made by this method weighs approximately seven to eight pounds. In one embodiment, at least portions of the upper surface  108  and/or lower surface  110  of the top frame  100  have an exterior skin which is rubberized or texturized to help prevent slippage between the top frame  100  and the load with which it is used. 
     In another embodiment, the finished foam top frame  100  may be coated with a polyurea material coating. The polyurea coating will increase the deflection strength of the top frame  100 , as well as increase its impact resistance, surface toughness, and wear resistance. In addition, the polyurea coating can have a textured surface to meet any desired friction characteristics. In an embodiment of the invention, a substrate such as a low, medium, or high density fiber board, or plywood can be coated with polyurea foam. A contemplated polyurea coating that may be used is Line-X or Bullet-Liner, available from Burtin Polymer Laboratories of Cartersville, Ga. 
     In an embodiment, the top frame  100  is molded using the same process as described above with respect to the pallet support board  10 . Similarly, the top frame  100  can be made from a foam or other substrate, and coated with polyurea material as disclosed above with respect to the pallet support board  10 . The polyurea material may be textured to include any desirable friction characteristics. 
       FIG. 14  is a perspective cross-sectional view of a top frame  100  made in accord with an embodiment of the present invention in which a self-skinning foam is used. The top frame  100  includes an outer layer or skin  111  formed by the process  600  of the present invention. The top frame  100  also includes an inner layer  105 . The inner layer  105  is essentially uniform in density, while the outer skin  111  is more dense than the inner layer  105 . The outer skin  111  is durable and hard to withstand and resist cuts, abrasions and wear. The pallet board  10 , pallet  200 , insulated tote  400 , and dolly  500  made with the self-skinning foam of this method will have a similar structure. 
       FIG. 9  shows a pallet  200  in accord with an embodiment of the present invention. The pallet  200  has a deck  202  with an inner layer  203  and outer surface  205  having an upper surface  204  and a lower surface  206 . Extending from the lower surface  206  are a plurality of legs  208 . The legs  208  support a load placed on the upper surface  204 . A thickness  210  extends between the upper surface  204  and lower surface  206 . A typical thickness  210  is on the order of ¼ to 1½ inches, but the deck  202  can be of any suitable thickness for its intended application. The deck  202  also includes a pair of opposing ends  212 , and a pair of opposing sides  214 . The pallet  200  can be made in any size suitable for its application. 
     In one embodiment, at least portions of the upper surface  204  and/or lower surface  206  of the pallet  200  have an exterior skin that is rubberized or texturized to help prevent slippage between the pallet  200  and the load with which it is used. In another embodiment, the upper surface  204  includes indented portions  218  corresponding to the legs  208  of a second pallet  200  for stacking one pallet  200  on top of another. 
     The pallet  200  is also made of a thermoset foam material. Suitable thermoset foam materials can include polyurethane foam, urethane foam, epoxy foam, phenolic foam, syntactic foam, polyaspartic foam, and hybrids of these foams. In a preferred embodiment, polyurethane foam is used. The polyurethane foam material is made in the same general process and with the same general characteristics as described above with respect to the pallet support board  10 . 
     In an embodiment, the foam varies in density along the thickness  210  of the deck  202  such that the density is greater nearest the outer surface  205 , including surfaces  204  and  206 , than in center of the thickness  210 . The density can vary continuously across the thickness  210 , or there can be two or more discrete layers of similar density, e.g., an inner density and an outer (i.e., skin) density. In other embodiments, the pallet  200  is a single density throughout the thickness  210 . The density of the foam material near the outer surface  205 , including surfaces  204  and  206  are such that the foam creates a hard outer shell. Such material may include a “self-skinning” foam as described above. 
     In another embodiment, the finished foam pallet  200  may be coated with a polyurea material coating. The polyurea coating will increase the deflection strength of the pallet  200 , as well as increase its impact resistance, surface toughness, and wear resistance. In addition, the polyurea coating can have a textured surface to meet any desired friction characteristics. In an embodiment of the invention, a substrate such as a low, medium, or high density fiber board, or plywood can be coated with polyurea foam. A contemplated polyurea coating that may be used is Line-X or Bullet-Liner, available from Burtin Polymer Laboratories of Cartersville, Ga. 
       FIGS. 18 through 20 and 22 through 23  show an insulated tote  400  of embodiments of the present invention. The tote  400  includes a pair of opposing side walls  402  and a pair of opposing end walls  404  and lid  406 . As shown in  FIGS. 22 and 34 , it also can include a lid  406  having a first side  408  and a second side  410 . 
     In one embodiment, the tote  400  includes a liner  412  made of a self-skinning rigid urethane foam as described above to form an inner layer  413  and outer surface  415 . It has been found that the self-skinning rigid urethane foam insulates better than current polystyrene liners, or other insulating materials. Moreover, the self-skinning foam is much more durable. Its hard outer skin is resistant to abrasions, cuts and wear. The liner  412  is sized and shaped to be inserted into the tote  400 . The tote  400  also includes a self-skinning urethane foam cover  414  to be placed on top of the liner  412 , and still allow the lid  406  to completely close. 
     In another embodiment, the tote  400  is completely made of self-skinning rigid urethane foam, including the side walls  402 , end walls  404 , and lid  406 . In a third embodiment, all but the lid  406  is made of self-skinning rigid urethane foam. The tote  400  in these two embodiments does not require a liner  412 , but one may be provided for additional insulation. 
     In a further embodiment a dolly  500  is provided in  FIGS. 16, 17 and 21 . The dolly  500  has includes a body  502 . The body  502  includes a caster  504  at each corner. The body  502  includes an elevated edge  506  and an opening  508  in its center. The body has an inner layer  510  and outer surface  512 . Current dollies are made using a rotomold or injection molding process known in the art. Current dollies are hollow and made of a thermoplastic. Dollies are subject to rough treatment. The dolly  500  of an embodiment of the present invention is made of the self-skinning urethane foam as described above to create the inner layer  510  and outer surface  512 . This provides a more durable dolly. The outer skin is hard and resists abrasions, cuts and wear better than thermoplastic dollies. 
     In one embodiment of the invention, the decks  12 , frame structure  106  and deck  202  of the pallet support board  10 , top frame  100 , and pallet  200  can include a reinforcing material disposed within their respective thicknesses  18 ,  112 , and  210 . The reinforcing material can be any one or more of woven or continuous strand glass matting, glass fiber, chopped fiberglass, metal tubing, plastic tubing, pultruded glass rod, graphite fibers, Honeywell&#39;s Spectra® brand polyethylene fibers, microballoons, nanomaterials, wood or balsa fragments or dust, polyester fibers or components, and shaped metal plates. Other suitable reinforcing materials can also be used. In a preferred embodiment, the reinforcing material is a fiberglass or polyester continuous strand mat or Hi-Lo fiberglass mesh. These reinforcing materials can be provided by Superior Fibers, LLC, of Bremen, Ohio or Fiberboard Industries of Amsterdam, N.Y. The material is placed in the mold before either injection or pouring. 
       FIGS. 10 through 13  show several examples of reinforcing materials that may be used with either of the pallet support board  10 , top frame  100 , or pallet  200 .  FIG. 10  shows in cross-section of thickness  18  of a deck  12  with a fiberglass matting or other fiber reinforcing material  300  disposed within. The matting or fiber  300  can be oriented to extend along one or more directions of the deck, or in a cross-hatch pattern. The matting  300  may or may not extend the entire length of the deck. 
       FIG. 11  shows in cross-section of thickness  18  of a deck  12  with a plurality of tubes  302  for reinforcing the deck  12 . The tubes  302  extend along preferably either the length or width of the deck  12 , but may be arranged in both directions. The tubes  302  may or may not extend the entire length of the deck. In embodiments of the invention, the tubes  302  can be made of plastic or metal, preferably steel, and can be in a variety of shapes. These shapes can include round, square, T-shapes, L-shapes, I-shaped, or any other suitable shape. 
       FIG. 12  shows in cross-section of thickness  18  of a deck  12  with a plurality of pultruded glass rods  304  for reinforcing the deck  12 . The rods  304  extend along preferably either the length or width of the deck  12 , but may be arranged in both directions. The rods  304  can be in a variety of shapes. These shapes can include round, square, T-shapes, L-shapes, I-shaped, or any other suitable shape. 
       FIG. 13  shows in cross-section of thickness  18  of a deck  12  with a plurality of plates  306  for reinforcing the deck  12 . The plates  306  extend along preferably either the length or width of the deck  12 , but may be arranged in both directions. The plates  306  may or may not extend the entire length of the deck. In embodiments of the invention, the plates  306  can be made of plastic or metal, preferably steel, and can be in a variety of shapes. These shapes can include M-shaped as shown, V-shaped, X-shaped, or any other suitable shape. 
     It will be understood that although  FIGS. 10 through 13  were discussed with respect to a deck  12  of a pallet support board  10 , the principles will apply equally to frame structure  106  and deck  202  of the top frame  100 , pallet  200 , insulated tote  400 , and dolly  500  embodiments. In an embodiment of the invention, the reinforcing materials are placed by hand in the tool cavity before the foam mixture is poured or injected into the tool cavity. Hand placement would be appropriate for larger reinforcing materials such as steel rods and glass matting. Alternatively, where the reinforcing material would permit, the reinforcing material can be mixed with foam mixture either prior to or during the injection molding process. 
       FIGS. 24-39  show examples of various transport items, including a top frame  100 , tote  400 , and pallet support board  10  that include a plurality of insertable components. In these examples, the components are shown as grommets  700 . Other insertable components such as casters, hinges, reinforcements, latches, gaskets, or similar items can also be used as desired based on the type of application. These insertable components can also be used with other thermoset foam transport items such dollies  500  or pallets  200 . The principles described below apply when the insertable components or grommets  700  are used with the other thermoset foam transport items. 
     As shown in  FIGS. 24 and 25 , the grommets  700  extend above and below top and bottom surfaces  704  and  706  of the top frame  100 . The grommets  700  are located at any desirable location within the transport items. For example, in the top frame  100  embodiments shown, the grommets  700  can further be located such that when top frames  100  are stacked, the grommets  700  of the top frame  100  contact grommets  700  above and below it. This provides separation between top frames  100  when stacked one upon the other. In other embodiments, the grommets  700  are located such they are compatible with automated packaging or other equipment with which the top frame  100  will be used. When used with other transport items, the grommets  700  can also be located within the pallet support board  10 , pallet  200 , tote  400  or dolly  500  such that they are compatible with items that will be placed upon or within them. 
     The grommets  700  can be made from rubber, urethane, or any suitable material. It is preferred that grommets  700  be made of a material having a higher coefficient of friction than the transport item material. It is also preferred that the grommet  700  be made of a material that will adhere or bond chemically or otherwise to the transport item material such that it is not easily dislodged therefrom. However, it is recognized that in certain applications it might be desirable that the grommets  700  have a lesser or equal coefficient of friction than the transport item material, and that the grommets  700  be easily removable from or rotatable within the transport item. 
     The grommets  700  can be made of any desirable shape such as a round or squared cylinder. In the embodiment of  FIGS. 31-33 , the grommet  700  is a round cylinder  708 .  FIG. 31  shows planes A, B, and C intersecting the grommet  700 . The cylinder  708  includes a pair of grooves  710  disposed towards either end  712  of the grommet  700 . The grooves  710  include inwardly sloping sides  714 . The angle of slope of the sides  714  is on the order of at minimum five degrees draft. The depth of the grooves  710  is preferably on the order of 0.03 inches to 0.25 inches. This range of angle and depth has been shown to adequately secure the grommet  700  within the top frame  100 . Other depths and angles may be used depending on the amount of mechanical securing desired. The angles and depths must also be chosen so as not to create abrupt angles that rather than securing the grommet  700  within the transport item, due to the brittleness of the thermoset foam material, would tend to break the material. 
     The grommet  700  also has cylindrical openings  716  and  718  at either end  712 . A through hole  722  is located in the center of the grommet  700 . The openings  716  cooperate with mold  800  to locate the grommets within the mold  800  and within the top frame  100  as described below. The grommet  700  includes at its ends  712  a slope portion  720 . At least part of the sloped portion  720  extends above and below the outer surfaces  704  and  706  of the top frame  100  as shown in  FIGS. 24 and 25 . 
     An example of integrating the grommets within a transport item is shown in  FIGS. 26-30 .  FIG. 26  shows a mold  800  for forming a top frame  100  including grommets  700 . The mold  800  includes a top portion  802  and a bottom portion  804 . The mold  800  is preferably made of metal such as steel or aluminum, but any suitable material can be used. The mold  800  also includes a nozzle  806  into which thermoset foam components are injected. The nozzle  806  communicates with the interior  808  of the mold  800 . The bottom portion  804  of the mold  800  includes a top frame bottom forming area  810  that corresponds to the shape of bottom portion of the top frame  100 . The top portion  802  includes a top forming area  812  that corresponds to the shape of the top portion of the top frame  100 . The forming areas  810  and  812  can include a texturized surface to create a texturized surface on the finished top frame  100 . 
     Within the bottom forming area  810  are a plurality of pegs  814 . The grommets  700  are placed on pegs  814  ( FIGS. 28 and 29 ) such that the pegs  814  are inserted into openings  716  or  718  to locate the grommets  700  within the mold  800  and within the finished top frame  100 . Pegs  814  may also be included on the top portion  802 . Note that the grommet is actually compressed down when the mold  800  is closed. In the top frame  100  application, the mold space in one embodiment is on the order of 1.0″ and the grommet is 1.125″ tall. This “seals” the foam material from getting on top of the grommet  700  as well as determines how much the grommet  700  protrudes above and below the other surfaces  704  and  706 . The grommets  700  may protrude above both the top and bottom surfaces  704  and  706  of the top frame  100 , or one or the other of these surfaces as desired. The protrusion allows the grommet  700  to contact items upon with the top frame  100  is placed, or to contact other grommets  700  when in use. 
       FIGS. 34-38  show the grommets  700  used with a tote  400 . The grommets  700  are located within one or both of the lid  406  or tote bottom  440 . The grommets  700  can extend above one or both of the upper and lower surfaces  442  and  444  of the lid  406  or  446  and  448  of the bottom  440 . 
       FIG. 39  shows grommets  700  within a pallet support board  10 . The same principles described above with respect to top frames  100  and totes  400  apply to use of grommets  700  in the pallet support board  10 , as well as any other desired transport item. 
     While the invention has been particularly described with respect to pallet support boards, top frames, pallets, dollies, and totes, the invention may also be used with other materials used to transport and store goods and materials, including top caps, bulk bins, or other suitable applications. Many of these items will be in one piece with each of the components integrally connected or formed with the other components. 
       FIGS. 40 and 41  show a gripper insert  800  within a pallet support board  10 . The gripper  800  includes a generally planar portion  802 . The gripper  800  can be made of any suitable material, include thermoplastic. Perpendicular to the planar portion  802  are a plurality of parallel fingers  804  located toward a first end  806  of the planar portion  802 . The fingers  804  are located and molded within the pallet support board  10 . The thermoset foam material of the pallet support board  10  fills interstices  808  between the fingers  804  to secure the gripper  800  within the board  10 . The gripper  800  can also be any desired shape outside the body of the pallet support board  10  that would be suitable to its purpose. 
     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying Claims.