Pallet and methods of making and using the same
First Claim
Patent Images
1. 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 thermoplastic 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, wherein the bottom deck comprises a second thermoplastic material; and
supporting columns disposed between the second wall and the bottom deck.
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Accused Products
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.
18 Citations
17 Claims
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1. A pallet, comprising:
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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 thermoplastic 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, wherein the bottom deck comprises a second thermoplastic material; and supporting columns disposed between the second wall and the bottom deck. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of making a pallet, comprising:
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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 thermoplastic 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, wherein the bottom deck comprises a second thermoplastic material; forming supporting columns between the second wall and the bottom deck. - View Dependent Claims (14, 15, 16, 17)
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Specification