PALLET AND METHODS OF MAKING AND USING THE SAME

• US 20130145971A1
• Filed: 12/03/2012
• Published: 06/13/2013
• Est. Priority Date: 12/07/2011
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: Sabic Innovative Plastics IP BV (Government of Saudi Arabia)
• Inventors: Buoniconti, Ralph Robert, Federl, Alan Robert
• Granted Patent: US 9,546,019 B2
• Time in Patent Office: Days
• US Class Current: 108/57.25
• CPC Class Codes: B65D 19/0059 forming a continuous plane contact surface
• CPC Class Codes: B65D 19/38 Details or accessories
• CPC Class Codes: B65D 2203/10 Transponders
• CPC Class Codes: B65D 2213/00 Safety means
• CPC Class Codes: B65D 2519/00024 Metal
• CPC Class Codes: B65D 2519/00034 Plastic
• CPC Class Codes: B65D 2519/00039 Agglomerates, i.e. different materials mixed together
• CPC Class Codes: B65D 2519/00044 Combination, e.g. different elements made of different materials, laminates
• CPC Class Codes: B65D 2519/00273 made of more than one piece
• CPC Class Codes: B65D 2519/00293 made of more than one piece
• CPC Class Codes: B65D 2519/00303 Cell type, e.g. honeycomb
• CPC Class Codes: B65D 2519/00318 made of one piece
• CPC Class Codes: B65D 2519/00343 contact surface being substantially in the form of a panel
• CPC Class Codes: B65D 2519/0086 Protection against environmental hazards, e.g. humidity, bacteria, fire
• CPC Class Codes: C08G 73/16 Polyester-imides
• CPC Class Codes: C08L 79/08 Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors

Abstract

In one embodiment, a pallet comprises a top deck comprising a substrate having a first surface and a second surface, wherein the substrate comprises a first plastic material; and a layer disposed on the second surface of the substrate, wherein the layer comprises a composition comprising reinforcing fibers, polyimide fibers, and polymeric binder fibers, wherein the polymeric binder fibers have a melting point that is lower than the polyimide fibers; a bottom deck; and supporting columns disposed between the second surface and the bottom deck.

Claims

1. A pallet, comprising:

a top deck comprising

a substrate having a first surface and a second surface, wherein the substrate comprises a first plastic material; and

a layer disposed on the second surface of the substrate, wherein the layer comprises a composition comprising reinforcing fibers, polyimide fibers, and polymeric binder fibers, wherein the polymeric binder fibers have a melting point that is lower than the polyimide fibers;

a bottom deck; and

supporting columns disposed between the second surface and the bottom deck.

2. The pallet of claim 1, wherein the second wall further comprises a plastic layer located on a side of the second wall adjacent the ribs.

3. The pallet of claim 1, wherein the reinforcing fibers are selected from the group consisting of metal fibers, metallized inorganic fibers, metallized synthetic fibers, synthetic fibers, glass fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, polymer fibers having a melt temperature at least 150°

C. higher than polyimide, and combinations comprising at least one of the foregoing.

4. The pallet of claim 3, wherein the reinforcing fibers comprise glass fibers.

5. The pallet of claim 1, wherein the first plastic material is selected from the group consisting of the group consisting of polyetherimide, polycarbonate, acrylonitrile-butadiene styrene, acrylic-styrene-acrylonitrile, polyphenylene oxide, polyurethane, polyester, polyethylene terephthalate, polypropylene, polyethylene, and combinations comprising at least one of the foregoing.

6. The pallet of claim 1, where in the bottom deck comprises a second plastic material, and wherein the first plastic material and the second plastic material are substantially free from a flame retardant additive.

7. The pallet of claim 1, wherein the pallet is free of polybrominated diphenyl ether.

8. The pallet of claim 1, wherein the pallet is free of decabromodiphenyl ether.

9. The pallet of claim 1, wherein the polyimide fibers comprise polyetherimide fibers.

10. The pallet of claim 1, wherein the pallet passes the idle test and the commodities test as set forth in UL 2335 (Second Edition, Jul. 28, 2010).

11. The pallet of claim 1, wherein the top deck further comprises a radio frequency identification tag.

12. The pallet of claim 12, wherein the radio frequency identification tag is located between the first wall and the second wall.

13. A pallet, comprising:

a top deck comprising a multiwall sheet, wherein the multiwall sheet comprises a first wall, a second wall, and ribs disposed between the first wall and the second wall, wherein the first wall and ribs comprise a first plastic material and wherein the second wall comprises a matrix layer comprising a dual matrix composite comprising a first matrix, a second matrix, and a network of fibers, wherein the network of fibers comprises polyimide fibers, polymeric binder fibers, and reinforcing fibers;

wherein the first matrix comprises melted and cooled polymeric binder and the second matrix comprises melted and cooled polyimide, wherein the polymeric binder fibers have a melt temperature lower than the polyimide fibers;

a bottom deck; and

supporting columns disposed between the second wall and the bottom deck.

14. A method of making a pallet, comprising:

forming a top deck comprising a multiwall sheet, wherein the multiwall sheet comprises a first wall, a second wall, and ribs disposed between the first wall and the second wall, wherein the first wall and ribs comprise a first plastic material and wherein the second wall comprises a matrix layer comprising a dual matrix composite comprising a first matrix, a second matrix, and a network of fibers, wherein the network of fibers comprise polyimide fibers, polymeric binder fibers, and reinforcing fibers;

wherein the first matrix comprises melted and cooled polymeric binder and the second matrix comprises melted and cooled polyimide, wherein the polymeric binder fibers have a melt temperature lower than the polyimide fibers;

forming a bottom deck;

forming supporting columns between the second wall and the bottom deck.

15. The method of claim 14, wherein the reinforcing fibers are selected from the group consisting of metal fibers, metallized inorganic fibers, metallized synthetic fibers, synthetic fibers, glass fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, polymer fibers having a melt temperature at least 150°

C. higher than polyimide, and combinations comprising at least one of the foregoing.

16. The method of claim 14, wherein the second wall expands when heat is applied to the pallet.

17. The method of claim 14, further comprising embedding a radio frequency identification tag into the top deck between the first wall and the second wall.

18. The method of claim 14, wherein the pallet passes the idle test and the commodities test as set forth in UL 2335 (Second Edition, Jul. 28, 2010).

19. A method of making a pallet, comprising:

forming a pallet comprising

a top deck comprising a multiwall sheet, wherein the multiwall sheet comprises a first wall, a second wall, and ribs disposed between the first wall and the second wall, wherein the first wall and ribs comprise a first plastic material and wherein the second wall comprises a matrix layer comprising a composition comprising reinforcing fibers, polyimide fibers, and polymeric binder fibers, wherein the polymeric binder fibers have a melt temperature lower than the polyimide fibers;

a bottom deck; and

supporting columns disposed between the second wall and the bottom deck; and

embedding a radio frequency identification tag in the top deck.

20. A pallet, comprising:

a top deck comprising

a substrate having a first surface and a second surface; and

wherein the top deck comprises a deck material selected from the group consisting of metal, wood, plastic, and combinations comprising at least one of the foregoing;

a bottom deck; and

supporting columns disposed between the second surface and the bottom deck;

wherein the pallet passes the idle test and the commodities test as set forth in UL 2335 (Second Edition, Jul. 28,

     2010).

21. The pallet of claim 20, wherein the substrate comprises a plastic material.

22. The pallet of claim 20, wherein the substrate comprises the deck material.

23. The pallet of any claim 20, wherein the deck material is in the form of a layer on the second surface.

24. The pallet of claim 23, wherein the layer extends across greater than or equal to 80% of the second surface.

25. The pallet of claim 20, wherein the deck material is selected from the group consisting of polyetherimide, polycarbonate, acrylonitrile-butadiene styrene, acrylic-styrene-acrylonitrile, polyphenylene oxide, polyurethane, polyester, polyethylene terephthalate, polypropylene, polyethylene, and combinations comprising at least one of the forgoing.

26. The pallet of claim 20, wherein the substrate, and/or the bottom deck, and/or the supporting columns are substantially free from a flame retardant additive.

27. The pallet of claim 20, wherein the deck material further comprises reinforcing fibers.

28. The pallet of claim 20, wherein the bottom deck comprises a second plastic material.