Abstract:
When a pallet is in use, goods to be shipped are generally mounted on the top surface. A pallet support formed from a polymer, preferable a fiber reinforced biopolymer, fits on the open end of the pallet, and adds great strength thereto, while still permitting a loaded pallet to be used in a standard fashion.

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
       [0001]    This Application claims the benefit of and priority to U.S. Utility patent application Ser. No. 12/137,689, filed Jun. 12, 2008, the entire disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to a pallet support and more particularly to a pallet support, which slides onto the pallet and increases the useful life of the pallet. 
         [0004]    2. Description of Related Art 
         [0005]    Shipping, for a wide variety of goods, is commonly done on a pallet. The pallet has a top and a bottom surface separated by a spacing mechanism. The bottom surface is generally in contact with the ground or another surface when the pallet is in use. When the pallet is not in use, a series of pallets may be stacked for storage or transportation. 
         [0006]    When the pallet is in use, goods to be shipped are generally mounted on the top surface. The spacing mechanism provides for the pallet and whatever is situated thereon to be lifted by a forklift or a similar device and transported to a desired position. This desired position may have a storage or a transport function. 
         [0007]    Clearly, the pallet is placed under severe physical stress in use. Thus, it is very desirable to reduce that physical stress in an inexpensive and efficient manner. To that end, various structures are known. However, the structures tend to be expensive and inefficient. 
         [0008]    In an effort to provide for an efficient use of resources, many pallet modifications are known. Typically, some sort of pallet support is placed over the end to protect the lifting side of the pallet, while at the same time, providing access thereto. With the pallet support in place, the pallet can last longer. With such efficiency, resources are used effectively. 
         [0009]    However, a critical part of the effective use of resources includes a careful consideration of the pallet support. The materials used to make the pallet must be environmentally advantageous. The method of making the pallet must be efficient. The energy consumed thereby must be less than the energy used in the overall process of setting up the pallet. 
         [0010]    Furthermore, if a plastic or synthetic resin material is used to make or reinforce the pallet, the overall environmental advantage can be compromised due to the petroleum base required therefor. Accordingly, rendering a pallet more durable becomes a very complicated matter. 
         [0011]    Clearly, these features can work against each other. Accordingly, great effort is required to determine which of the features can have which effect on the entire process. Each step of the process must be analyzed for the purpose of maximizing the efficiency of the entire situation. 
       SUMMARY OF THE INVENTION 
       [0012]    Among the many objectives of the present invention is the provision of a pallet support, which reinforces the pallet. 
         [0013]    Another objective of the present invention is the provision of a pallet support, which increases the useful life of the pallet. 
         [0014]    Yet another objective of the present invention is the provision of a pallet support, which reduces the use of petrochemicals. 
         [0015]    Still, another objective of the present invention is the provision of a pallet support, which efficiently uses resources in manufacturing the pallet support. 
         [0016]    These and other objectives of the invention (which other objectives become clear by consideration of the specification, claims and drawings as a whole) are met by providing a pallet support, formed from a composite material or polymer; especially a fiber reinforced, biopolymer. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0017]      FIG. 1  depicts an exploded perspective view of the four runner pallet support  100  of this invention on pallet  102 . 
           [0018]      FIG. 2  depicts a top plan of the four runner pallet support  100  of this invention on pallet  102  based on  FIG. 1 . 
           [0019]      FIG. 3  depicts a top perspective view of the four runner pallet support  100  of this invention. 
           [0020]      FIG. 4  depicts a rear perspective view of the four runner pallet support  100  of this invention. 
           [0021]      FIG. 5  depicts a bottom, plan view of the four runner pallet support  100  of this invention. 
           [0022]      FIG. 6  depicts a top plan view of the four runner pallet support  100  of this invention. 
           [0023]      FIG. 7  depicts a cross section view of the three runner pallet support  100  of this invention. 
           [0024]      FIG. 8  depicts a front plan view of the three runner pallet support  200  of this invention in cross-section. 
           [0025]      FIG. 9  depicts a cross section view of the three runner pallet support  200  of this invention along Line  9 - 9  in  FIG. 8 . 
           [0026]      FIG. 10  depicts an interior, close-up, plan view of honeycomb  170  of the pallet support  100  of this invention. 
           [0027]      FIG. 11  depicts an interior plan view of the center portion of pallet support  100  of this invention. 
           [0028]      FIG. 12  depicts the pallet support  100  of this invention on a pallet  102  in a block diagram form. 
       
    
    
       [0029]    Throughout the figures of the drawings, where the same part appears in more than one figure of the drawings, the same number is applied thereto. 
       DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    Reference will now be made in detail to several embodiments of the invention that are illustrated in accompanying drawings. Whenever possible, the same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps. The drawings are in simplified form and are not to precise scale. For purposes of convenience and clarity only, directional terms such as top, bottom, left, right, up, over, above, below, beneath, rear, and front, may be used with respect to the drawings. These and similar to directional terms are not to be construed to limit the scope of the invention in any manner. The words attach, connect, couple, and similar terms with their inflectional morphemes do not necessarily denote direct or intermediate connections, but may also include connections through mediate elements or devices. 
         [0031]    The pallet support of this invention is formed of a composite material, which is durable and designed for use with a forklift or other uses. As a composite material, use of petroleum based resins can be minimized, and recycled materials or polymers can be used to form the pallet support. Compression molding of the composite material can form the pallet support into a desired shape for the strength to be used with a pallet and extend the life thereof. 
         [0032]    Composite materials are created by combining two or more materials to produce a new material that retains important properties from the original components, and may even provide a stronger material. These unique combinations deliver significant advantages over traditional materials in a wide variety of structural applications. Composites consist of a resin, a polymer, a matrix material or combinations thereof, that is then reinforced with fibers that can be taken from ceramics, metals, or polymers. The reinforcing fibers are the primary load carriers of the material, with the matrix component or polymer of pallet support transferring the load thereon from fiber to fiber. 
         [0033]    In a preferred form, this pallet support encapsulates an exposed portion of the two inches by four inches (two by four ends) wood stringers of the pallet, and replaces the top and bottom board on each end of the pallet. Removal of the end boards, creates that exposed portion to receive the pallet support. 
         [0034]    If the pallet has no top end board and no bottom end board on each end of the support boards or stringers of the pallets, such removal is not required to use the pallet support. For conversion of a standard pallet to use the pallet support, such removal is highly preferred, if not required. 
         [0035]    The pallet support may fit over the pallet without the removal of the top end board and the bottom end board, that is with the top end board and the bottom end board still in place. This requires slot modification and weakening of the pallet support which is not desired. 
         [0036]    In a standard drop test, there is no damage from a corner drop or dropping pallet with the pallet support in place on a corner thereof. Such encapsulation minimizes the common industry pallet failure known as out of square damage, that is changing of the ninety degree angles at each corner of the pallet. This feature is important because over ninety (90%) percent of pallet damage comes from the “out of square”, and destruction of the lead boards and two by four ends. 
         [0037]    The encapsulation of the pallet by the pallet support also minimizes breakage of the pallet itself. This bio-composite polypropylene blend is so strong or super tough, that it is actually used for auto bumpers and running boards. Rackability is extremely important and a great benefit in the pallet industry. This pallet provides rack ability and retains full rack strength because it utilizes the full length wood two by four present in the pallet. Full plastic pallets do not have near the same rack able strength as wooden pallets. So this pallet support provides the best of both worlds. 
         [0038]    Reinforcement of the matrix material can be achieved in a variety of ways including particles. Fibers may be continuous or discontinuous with the matrix material, which is usually obtained from one of the many available engineering polymers. 
         [0039]    Manufacturers&#39; composites offer a flexible solution with the advantage of being able to select just the right combination of fiber reinforcement and resin material to meet both the application and property requirements of a finished part. 
         [0040]    Referring now to  FIG. 1 ,  FIG. 2  and  FIG. 5 , the structure of the pallet support  100  with pallet  102  thereon is shown. With end top board  114  and end bottom board  116  and back end top board  115  and back end bottom board  117 —removed from top platform  106  and bottom platform  112  respectively, four runner pallet support  100  fits over first center board  108  and the optional second center board  110  as well as with the first support board  118  and second support board on either side thereof. First center board  108  and the optional second center board  110  as well as with the first support board  118  and second support board  119  are usually two inches by four inches common in the lumber industry. 
         [0041]    Adding  FIG. 3 ,  FIG. 4 ,  FIG. 5  and  FIG. 6 , the structure of the four runner pallet support  100  for pallet  102  is shown. Four runner pallet support  100  has an open side  120  to receive a pallet  102 , and a closed side  140  to limit the insertion of pallet  102 . Within open side  120  are a first closed end slot  122  with a second closed end slot  124  oppositely disposed therefrom. With four runner pallet support  100  in place on pallet  102 , each of first closed end slot  122  and second closed end slot  124  receives first support board  118  and second support board  119  respectively. 
         [0042]    From open side  120 , both first closed end slot  122  and second closed end slot  124  include end gripping ribs  126 , preferably on three sides thereof. The gripping ribs  126  contact first support board  118  and second support board  119  of the pallet  102  in order to support four runner pallet support  100  on pallet  102 . 
         [0043]    In a like manner from open side  120 , between first closed end slot  122  and second closed end slot  124 , first interior slot  130  and optional interior slot  132  provide a grip on first center board  108  and optional second center board  110 , when four runner pallet support  100  is secured to pallet  102 . Interior ribs  136  are present in first interior slot  130  and optional second interior slot  132  to serve the same function as end gripping ribs  126 . First interior slot  130  and optional interior slot  132  have interior ribs  136  ( FIG. 11 ), which grip first center board  108  and optional second center board  110 . 
         [0044]    Closed side  140  has tong openings  142  to receive the tongs  144  of the forklift  146  ( FIG. 12 ). However, first closed end slot  122 , second closed end slot  124 , first interior slot  130 , optional second interior slot  132 , end gripping ribs  126 , and interior ribs  136  are preferably closed on closed side  140 . This facilitates mounting of the four runner pallet support  100  on pallet  102 . 
         [0045]    To facilitate the application of four runner pallet support  100  to pallet  102 , end top board  114  and end bottom board  116  are removed from pallet  102  ( FIG. 1 ). Pallet support  100  then receives first support board  118 , second support board  119 , first center board  108 , and second center board  110  of pallet  102  more efficiently. In this manner, pallet support  100  being applied to pallet  102  is greatly facilitated. 
         [0046]    Turning now to  FIG. 7 ,  FIG. 8 , and  FIG. 9 , three runner pallet support  200  adapted to receive first support board  118  and second support board  119 , which are usually two inches by four inches. However, only first interior slot  130  is present, because only first center board  108  is present in the pallet  102  ( FIG. 1  and  FIG. 2 ). Thus, second interior slot  132  and second center board  110  are removed from this embodiment. 
         [0047]    Adding  FIG. 10  to the consideration, raised ribs  150  in either a square or a hexagonal pattern form honeycomb pattern  170 , which provides support for the pallet support  100  on open side  120 . Gripping ribs  126  ( FIG. 4 ) and interior ribs  136  ( FIG. 4 ) also add to the strength of the pallet support  100 , as well as improving the grip of pallet support  100  on pallet  102 . This structure also provides for a reduction in material use for the pallet support  100 , while retaining the strength thereof. 
         [0048]    Adding  FIG. 11  to the consideration, the structure of first interior slot  130  and second interior slot  132  can be clearly seen. First interior slot  130  and second interior slot  132  have interior ribs  136  which improve the grip of pallet support  100  on pallet  102 . 
         [0049]    With the consideration of  FIG. 12 , reconfigurations of pallet  102  can be considered. When such reconfigurations occur, appropriate adjustments in the pallet support  100  can also be made. If only first center board  108  is present without second center board  110 , first center board  108  is more centrally located between first support board  118  and second support board  119 , which are on other side thereof. By that same token, end top board  114  and end bottom board  116  or back end top board  115  and back end bottom board  117  may be left in place if open side  120  is a little wider. In the same manner first closed end slot  122  and second closed end slot  124  can be adjusted. 
         [0050]    However, first center board  108  and second center board  110  with end top board  114  and end bottom board  116  removed give the best results. The pallet support  100  is most useful such a structure for pallet  102 . 
         [0051]    Closed side  140  for pallet support  100  includes tong openings  142  for the tongs  144  of a forklift  146  or other lifting device. In this fashion, as pallet support  100  is applied to pallet  102 , pallet  102  can still be lifted or used in its standard fashion, but with the pallet  102  having pallet support  100  thereon with much greater durability. 
         [0052]    In the following examples, which are illustrate without unduly limiting the invention, all parts and percentages are by weight, unless otherwise specified. 
       EXAMPLE 1 
       [0053]    A polyurethane foam is prepared by blending the following. Composite materials being petrochemical based have two large disadvantages. First, this is a limited resource whose growing consumption negatively affects almost all aspects of our lives. Second, the increasing cost of petro-based composite materials diminishes the commercialization of composites into new products and prevents customers from realizing the benefits of composite materials. Composite manufacturing utilizing agricultural input materials reduce the relative content of petrochemicals and reduce the cost of the base material while promoting renewable sources. 
         [0054]    In two structural tests, the bio-composite pallet performance is equivalent to the baseline composite pallet. The tests consist of loading the pallet in a test machine to represent a concentrated load and measuring the deflection of the pallet. The first test represented the load on a pallet while on the forks of a lift. The bio-composite pallet deflected the same amount as the baseline composite pallet: The second test represented a load on the pallet while the pallet is on the storage rack. The bio-composite pallet performed slightly better than the baseline pallet since it had less deflection. 
         [0055]    Forklift Load-DeflectionTesting is based upon ASTM D1185 “Standard Test Methods for Pallets and Related Structures Employed in Materials Handling &amp; Shipping”. The base of the pallet was supported on beams spaced 27″ apart to simulate forks from a lift. 
         [0056]    A compressive load is applied down the center of the pallet on a plate parallel to the supports at 0.5 inches per minute. The load is applied also along the edges of the pallet deck parallel to the simulated forks. Test results are below. 
         [0057]    Rack Load-Deflection 
         [0058]    Testing is based upon ASTM D1185 “Standard Test Methods for Pallets and Related Structures Employed in Materials Handling &amp; Shipping”. The pallet is placed on rack beam simulators. Two parallel line loads are centered on the test pallets. The line loads are spaced at a distance equal to half the width of the pallet. A compressive force is applied at a constant rate of 0.5 inches per minute. Test results are below. 
       EXAMPLE 2 
     Top to Bottom Compression 
       [0059]    Testing is based upon ASTM D642 “Standard Test Method for Determining Compressive Resistance of Shipping Containers, Components, and Unit Loads”. Pallets and Related Structures Employed in Materials Handling &amp; Shipping”. 
         [0060]    Boards are placed on the pallet deck to uniformly distribute the load. A compressive force is applied at a constant rate of 0.5 inches per minute until 20 force capacity static load of 7,000 pounds was reached. There is no noticeable difference between the baseline and bio-composite pallet. 
       EXAMPLE 2 
     Compression Strength of Legs 
       [0061]    Testing is based upon ASTM D1185 Standard Test Methods for Pallets and Related Structures Employed in Materials Handling &amp; Shipping”. The pallet is placed on rack beam simulators. Two parallel line loads are centered on the test pallets. The line loads are spaced at a distance equal to half the width of the pallet. A compressive force is applied at a constant rate of 0.5 inches/minute. The procedure is performed on the center, middle, and corner leg on the edge of the pallet. There is no noticeable difference between the baseline and bio-composite pallet. 
       EXAMPLE 3 
     Impact 
       [0062]    The pallet is kept at temperature range of plus or minus degree of minus 15 degrees Fahrenheit for a period of 56 hours. The pallet is: 
         [0063]    A. Flat dropped on bottom from 8 feet. 
         [0064]    B. Flat dropped on top from 8 feet. 
         [0065]    C. Dropped on both sides (48″ and 40″) from 10 feet. 
         [0066]    D. Dropped on one corner twice, from 10 feet, and then 15 feet. 
         [0067]    No failure is noted. Failure is defined as any change in the geometry of the pallet that prevents normal operation, truck handling, stacking, or structural damage exceeding 1.5 inches squared. 
       EXAMPLE 4 
       [0068]    The procedure of Example 1 is repeated, but for the fibers being removed from the resin. When the pallet is tested with the modified pallet support, the pallet fails the tests. 
         [0069]    This application—taken as a whole with the abstract, specification, claims, and drawings—provides sufficient information for a person having ordinary skill in the art to practice the invention disclosed and claimed herein. Any measures necessary to practice this invention are well within the skill of a person having ordinary skill in this art after that person has made a careful study of this disclosure. 
         [0070]    Because of this disclosure and solely because of this disclosure, modification of this tool can become clear to a person having ordinary skill in this particular art. Such modifications are clearly covered by this disclosure.