Load-bearing structure

Abstract

The present invention provides a load-bearing structure, which includes: a polymer core, the polymer core having a top side, a bottom side and a width portion, the width portion having a thickness connecting the top side and the bottom side, the bottom side including at least one recess extending substantially along the length or width of the bottom side, the at least one recess including one recess, a group of closely spaced recesses, or a combination of one recess and a group of closely spaced recesses; at least one corresponding component cooperating with one of the at least one recess, the corresponding component including at least one raised center portion and two flat side portions extending from both sides of the raised center portion; at least one polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being combined with the bottom side, the width portion and at least a portion of the top side of the polymer core.

Description

[0001] This application is a divisional application of the invention patent application with application number "201810445379.5", application date May 11, 2018, and invention name "Bearing Structure".

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 505,112, filed on May 11, 2017, entitled “LOAD BEARING STRUCTURE,” which is hereby incorporated by reference in its entirety into this application. Technical Field

[0004] The present invention relates to the general field of load-bearing structures, and in particular, to a load-bearing structure for loading, storing and / or transporting goods. Background Art

[0005] A shipping pallet is a well-known load-bearing, movable platform on which loaded goods are placed. A pallet is usually loaded with different items such as crates or boxes. A loaded pallet can be moved by a pallet truck or lift.

[0006] The adoption of International Standardized Phytosanitary Monitoring (ISPM)-15 for Wood Packaging Material (WPM) requires kiln drying of all wood used in shipping boxes and pallet platforms (pallets).

[0007] The United States, in partnership with Mexico and Canada, began enforcing the ISPM 15 standard on September 16, 2005. The North American Plant Protection Organization (NAPPO) strategy for increased enforcement will be implemented in three phases. Phase 1, September 16, 2005 to January 31, 2006, requires enforcement through account managers and notices affixed to WPMs containing non-compliant products. Phase 2, February 1, 2006 to July 4, 2006, requires the rejection of non-compliant crates and pallets exported from North America. Enforcement will continue through account managers and notices affixed to shipments with other types of non-compliant WPMs. Phase 3, July 5, 2006, includes full enforcement of regulations governing WPMs entering North America. Non-compliant WPMs will not be allowed into the United States. The adoption of ISPM-15 reflects the growing concern among countries about wood-based transport products that could import wood-boring insects, including the Asian Long horned Beetle, Asian Cerambycid Beetle, Pine Wood Nematode, Pine Wilt Nematode and Anoplophora Glapripwnnis.

[0008] Therefore, wooden pallet platforms have become unattractive for international transportation of products. In addition, wooden surfaces are unhygienic because they can harbor mold and bacteria in addition to insects. Therefore, wooden crates are generally not suitable for shipping food and other products that require hygienic conditions. In addition, considering carbon emissions, there is a greater need for lighter weight platforms and crates.

[0009] Plastic pad platforms or trays are known, see U.S. Pat. No. 3,915,089 to Nania and U.S. Pat. No. 6,216,608 to Woods et al., both of which are incorporated herein by reference in their entirety. Thermoplastic molded pad platforms are known, see, for example, U.S. Pat. Nos. 6,786,992, 7,128,797, 7,927,677, 7,611,596, 7,923,087, 8,142,589, 8,163,363, and 7,544,262 to Dummett, which are incorporated herein by reference in their entirety, which disclose the use of thermoplastic sheets to make preformed rigid structures for pad platforms. Other disclosures include U.S. Pat. Nos. 8,244,602 and 8244,721, both of which are incorporated herein by reference in their entirety. Summary of the invention

[0010] According to one aspect of the present invention, there is provided a load-bearing structure, the load-bearing structure comprising: a polymer core, the polymer core having a top side, a bottom side and a width portion, the width portion having a thickness connecting the top side and the bottom side, the bottom side comprising at least one recess extending substantially along the length or width of the bottom side, the at least one recess comprising one recess, a group of closely spaced recesses, or a combination of one recess and a group of closely spaced recesses; at least one corresponding member cooperating with one of the at least one recess, the corresponding member comprising at least one raised portion and two flat side portions extending from both sides of the raised portion, the flat side portions and the raised portion being integrally formed; and at least one polymer sheet, the polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being combined with at least a portion of the top side, the bottom side and the width portion of the polymer core.

[0011] According to another aspect of the present invention, there is provided a load-bearing structure having a top side, a bottom side and a width portion located between the top side and the bottom side, the load-bearing structure comprising: a foam polymer core, the foam polymer core having a top side, a bottom side and a width portion, the width portion of the foam polymer core having a thickness connecting the top side of the foam polymer core and the bottom side of the foam polymer core, the foam polymer core having an outer edge, the bottom side comprising: a plurality of support members, the plurality of support members extending orthogonally from the bottom side of the core; at least one recess extending between adjacent support members; and at least one recess extending substantially along the length or width of the bottom side, the at least one recess extending substantially along the length or width of the bottom side comprising a single recess or a group of closely spaced recesses; corresponding components, the The corresponding component cooperates with the at least one recess, and the corresponding component has a raised portion formed integrally with two flat side portions; a first polymer sheet, the first polymer sheet having a first side and a second side with an outer edge portion, the first side and its outer edge portion are respectively combined with at least a portion of the thickness of the width portion of the foam polymer core, the bottom side and the multiple support members; and a second polymer sheet, the second polymer sheet having a first side and a second side with an outer edge portion, the second side and its outer edge portion are respectively combined with the foam polymer core on at least a portion of the thickness of the width portion of the foam polymer core and the top side, thereby forming an overlap around the width portion between the outer edge portion of the first polymer sheet and the outer edge portion of the second polymer sheet.

[0012] According to another aspect of the present invention, there is provided a load-bearing structure, the load-bearing structure comprising: a polymer core, the polymer core having a top side with an outer edge, a bottom side with an outer edge and a width portion, the width portion having a thickness connecting the top side and the bottom side, at least a portion of at least one of the outer edges comprising a roughened edge portion; a plurality of supports, the plurality of supports extending orthogonally from the bottom side of the polymer core; and at least one polymer sheet, the polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being combined with at least a portion of the top side of the polymer core, the bottom side, the plurality of supports and the width portion; wherein the roughened edge portion is arranged on the outer edge of the polymer core between adjacent supports, and the roughened edge comprises a notch.

[0013] The present invention relates to a load bearing structure having a thinner core, substantially the same or less overall weight, while having improvements in supporting cargo. The load bearing structure has a top side and a bottom side, while having a width between the top side and the bottom side connecting the thickness of the two. The load bearing structure may or may not include a plurality of supports or extensions, and the supports or extensions, if present, may extend from the bottom side of the load bearing structure in a substantially vertical direction.

[0014] Load bearing structures are often used to transport goods by air, land, such as by truck or rail, or by sea. In any mode of transport, the weight of the load bearing structure often affects the cost of transporting the goods. This is especially true for air transport. At the same time, the load bearing structure needs to be durable and adaptable to rough handling. In order to have a lighter weight, the load bearing structure can be composed of a lightweight polymer core, which can be covered or combined with one or more polymer sheets or films to increase strength and durability. In order to further improve the load bearing capacity, a denser core (described in more detail below) or a thicker or multi-layered covering film or covering sheet can also be used, which often increases costs and makes the load bearing structure heavier.

[0015] In addition to the higher weight, a thicker core also reduces the amount of cargo that can be packed onto the load-bearing structure. For example, for air shipment of cargo, not only is weight an important factor, but cargo space is also limited, both vertically and horizontally. For a load-bearing structure of the same width, a thicker core leaves less vertical space for cargo, while a thinner core leaves more space for cargo. However, a thinner core also generally results in lower strength and may only be able to carry lighter cargo. Considering transportation efficiency, it is usually necessary to carry as much cargo as possible based on the mass loaded onto the load-bearing structure without affecting the integrity of the load-bearing structure.

[0016] The present invention also relates to a load-bearing structure as described above that further improves the required load-bearing capacity and has a substantially same weight and thinner core, the load-bearing structure including at least one depression, such as a groove, a valley, an indentation or a channel, located on the lower side or bottom surface of the core, the at least one depression cooperating with at least one corresponding member. The core can have substantially the same density as a thicker core or a heavier core. The lighter the overall weight, the better for transporting goods using the load-bearing structure, especially for air transportation, where lighter weight can save costs or the overall weight of concern becomes more important, as long as the overall strength of the load-bearing structure is not affected. In some exemplary embodiments, the load-bearing structure of the present invention can be composed of a lightweight polymer core, the lightweight polymer core having a density, for example, between about 20 g / cc and about 35 g / cc, for example, between about 21 g / cc and about 30 g / cc, for example, between about 23 g / cc and about 25 g / cc, the lightweight polymer core having a surface or surfaces covered with one or more polymer sheets or films or combined with one or more polymer sheets or films. By providing the core with at least one depression on the underside of the core, for example a groove, valley, indentation or channel and at least one corresponding component cooperating with the at least one groove, valley, indentation or channel, further improvements in load-bearing capacity, such as the ability to transport greater weights or increased rigidity or strength, can be achieved without making the load-bearing structure heavier.

[0017] In some cases, the improved load-bearing characteristics of the load-bearing structure of the present invention having a reduced overall thickness and / or weight may actually allow a carrier to ship additional or more rows of product per load-bearing structure without adding weight, or with as little weight increase as possible, thereby further saving costs, for example in air shipment of cargo such as smartphones, sheet materials, or other similar thin products.

[0018] The one or more depressions may be of any length or width and may be arranged anywhere on the bottom side of the core or the load-bearing structure. For example, the length may be substantially the same as the longitudinal and transverse dimensions of the core or slightly shorter. For another example, the length may be only as long as the distance between the supports or extensions (if any). Long depressions (if any) may further improve the strength of the load-bearing structure when coupled with corresponding components.

[0019] In one example, the pallet of the present invention may include a thinner polymer core having at least one pair of long depressions that cooperate with corresponding components, the long depressions spanning the length or width of the core, for example, at least about 75%, for example, at least about 80%, or even for example, at least about 85%. The load-bearing capacity of these structures is maintained, even when the overall weight of the load-bearing structure is much lower than the overall weight (with higher weight and / or greater thickness) when such depressions are not matched with corresponding components. The load-bearing capacity can be measured by a deflection test, as discussed in more detail below. For example, when cargo is loaded onto the load-bearing structure, the cargo-loaded structure is kept aside for a period of time during transportation or storage. After being kept aside for a long time, for example, at least one day, for example, at least three days, or even more, for example, at least seven days, the structure tends to undergo some deformation, such as bending. The longer the cargo is kept aside, the more bending occurs. It is found that the deformation after a few hours or days is within an acceptable range by using a pair of longer depressions on the lower side of the core. In fact, with some load-bearing structures having only a pair of well-placed longer recesses, each cooperating with a corresponding member, the deformations remain within acceptable limits, even without the need for additional shorter recesses or cooperating members.

[0020] The longer depressions may be spaced apart from each other and substantially parallel to each other, extending substantially along the width or breadth of the bottom side of the core.As noted above, each depression may comprise a single depression or a group of closely spaced depressions.

[0021] In one aspect, at least one depression (long or short) may include one or more depressions spaced apart from one another on the underside of the polymer core. If more than one depression is present, not all depressions must have the same length, shape, or depth. In one embodiment, a corresponding member may mate with all depressions present. In another embodiment, not all depressions (if more than one is present) mate with a corresponding member.

[0022] Each member (if there is more than one depression that matches the member) can include a raised portion, which in some examples is a roughly central portion, which can have a cross-section of any shape with or without a flat portion such as a wing-shaped member extending from the lower portion on both sides of the raised portion, for example, a substantially dome-shaped or semicircular cross-section, a substantially rectangular cross-section, a substantially triangular cross-section, or a similar cross-section. The raised portion can have straight side walls or tapered side walls. When matched, the raised portion can be substantially inserted into one of at least one correspondingly shaped groove, valley, indentation, or channel. The raised portion and wing-shaped portion, if present, can be directly or indirectly adhered or bonded to the lower side of the polymer core. In one embodiment, the member can cover the polymer core or be bonded to the polymer core before covering the polymer core with one or more polymer sheets or films or bonding to the polymer core. In another embodiment, the member can cover the load-bearing structure or be bonded to the load-bearing structure after covering the polymer core with one or more polymer sheets or films or bonding to the polymer core.

[0023] In another aspect, at least one depression may include one or more groups of closely spaced parallel depressions, such as grooves, valleys, indentations, or channels. The depressions within a group may or may not have the same length, shape, or depth. The internal spacing between a group of depressions may be smaller than the spacing between adjacent groups (if any). In other words, the spacing of parallel depressions within a group may be smaller than the spacing between two separate grooves (if any) that are not within a group. The group of depressions may also be interspersed with a single depression.

[0024] In one embodiment, the corresponding member may cooperate with all the recesses present. In another embodiment, not all groups of recesses (if more than one group exists) cooperate with the corresponding member. In yet another embodiment, not all recesses within a group cooperate with the member.

[0025] The corresponding member for each recess, whether or not the recess is part of a group, may include at least one raised central portion for each recess. The member for a group of recesses (if all recesses in a group are matched with the member) may include at least one raised central portion, or at least two raised central portions, which may have a cross-section of any shape or any combination of shapes, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section, or the like, with or without a flat portion, such as a wing-shaped member, extending from the lower portion on both sides of the raised portion. As noted, the raised portion may have straight side walls or tapered side walls. If there is one or more than one group, the raised portion may have a cross-section of any shape or any combination of shapes, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section, or the like, with or without a flat portion, such as a wing-shaped member, extending from the lower portion on both sides of the raised portion. When matched, the raised portion may be substantially inserted into one of the grooves, valleys, indentations, or channels of at least one corresponding shape. The raised portions and wings, if present, may be adhered or bonded directly or indirectly to the underside of the polymer core. In one embodiment, the member may cover or bond to the polymer core before covering or bonding the polymer core with one or more polymer sheets or films. In another embodiment, the member may cover or bond to the load-bearing structure after covering or bonding the polymer core with one or more polymer sheets or films.

[0026] In one example, at least one recess substantially spans at least about 75%, at least about 80%, or even at least about 85% of the length or width of the load-bearing structure. A recess may include a single recess or a group of closely spaced parallel recesses, all of which have the same length but may or may not have the same width or depth.

[0027] The polymeric core may or may not include extensions extending from the bottom of the polymeric core, as described above, and the supports or extensions, if present, may extend from the bottom side of the load-bearing structure in a substantially vertical direction.

[0028] According to one aspect of any one of the embodiments, the member can be a solid structure. According to another aspect of any one of the embodiments, the member can include any degree of internal hollowness in the center portion, such as a dome-shaped portion or other portion, to reduce the weight of the resulting load-bearing structure. Surprisingly, the use of a hollowed-out center portion does not impair the ability to improve the resulting load-bearing structure, such as the ability to transport heavier objects.

[0029] The wing-like member, if present, may be of a small thickness so that after the member is fitted together with the groove or the like, and before or after the polymer core is bonded to or covered with a thermoplastic sheet or film, the resulting combination may be substantially flush with the remainder of the underside of the polymer core where the member is not present. Generally, whether the center portion is solid or hollowed out to any extent, the underside of the resulting load-bearing structure may have a relatively smooth feel with very little visible ridges or bumps. A load-bearing structure having at least one groove on the underside of the polymer core and the at least one groove bonded to or covered by at least one member has improved properties, such as being able to transport more weight than a load-bearing structure without the groove.

[0030] The shape and / or size of the component may mirror the depression or groove on the underside of the polymer core. This enables the component to be securely placed in the depression without the aid of additional adhesion or bonding means, such as adhesives and / or heating. The component may also be made to snap into place in the depression. In addition, the component may be even more securely placed when mated before covering the core with the polymer sheet.

[0031] The wing-like members, if present, can help the member adhere or bond to the underside of the load-bearing structure, or to the core or film or sheet, depending on whether the member is attached before or after covering or bonding to the core with the sheet or film. The wing-like members can also be tapered towards the ends to provide a smoother transition of the member to the underside of the core.

[0032] In one embodiment, when a wing-like member is present, the configuration of the depression, such as a valley, indentation, or channel, can be the same as the configuration of the depression when the wing-like member is not present. The wing-like member can be located on top of the underside of the load-bearing structure, or on top of the core or cover film or cover sheet. After bonding or bonding, the bottom side of the load-bearing structure can present a substantially smooth feel or appearance as described above. In another embodiment, when a wing-like member is present, the depression (e.g., valley, indentation, or channel) can be modified, such as dented, to accommodate the wing-like member so that the member with the wing-like member can be completely flush with the bottom side. After bonding or bonding, the bottom side of the load-bearing structure can present a substantially smooth feel or appearance.

[0033] When an extension is present, the extension may be partially or substantially entirely hollow. The cavity portion may be bottom-oriented to form a depression such as a valley, indentation, or channel on the bottom surface of the extension, and the cavity portion may cooperate with a similar component as described above so that after being combined or bonded with the component, the bottom of the extension presents a substantially smooth feel or appearance without any indication that it is a cavity. The cavity extension also helps to reduce the weight of the load-bearing structure. Surprisingly, the cavity extension in conjunction with the corresponding component does not impair the load-bearing capacity, and in some embodiments, actually helps to improve the load-bearing capacity.

[0034] Although the interior of the extension is a cavity, when the polymer core is combined with a thermoplastic film or sheet, i.e., during the thermoforming process, the cooperation of the extension with the corresponding components can present an exterior that is substantially similar to a polymer core with a solid extension. As mentioned above, the cooperation of these components can also occur after the bonding process.

[0035] The extension can be hollowed out when the core is manufactured or after the core is manufactured. It may be easier and save time to construct the hollowed-out extension during manufacturing.

[0036] In one embodiment, the hollowing out can occur over substantially the entire length of the extension and can be shaped into a corresponding member to fit substantially the entire recess. In one aspect, the member can be hollowed out as described above. In another aspect, the member can be solid. In another embodiment, the recess or hollowing out of the extension can be partial.

[0037] The interior of the cavity may also be tapered. In one aspect, the taper may be toward the bottom. In another aspect, the taper may be toward the top. Tapering toward the top may make it easier to fit with the member, and the member may substantially fill the cavity space of the extension. It may be tapered toward the bottom, but the extension may not substantially fill the space inside the cavity, and the member may not substantially correspond to the shape of the recess, making it easier to insert the member into the recess. When tapered, the member also tapers accordingly, thereby better fitting with the recess. As described above, the member may also include a cavity center portion to minimize the weight of the entire construction.

[0038] As mentioned above, the hollow interior of the extension and the member also help to reduce the weight of the load-bearing structure without substantially affecting the load-bearing performance of the structure. In fact, the load-bearing performance may be enhanced.

[0039] The length of the member can be customized by any method. It can be manufactured in the required length or in batches and then cut to fit the length of the depressions to be matched, such as grooves, valleys or channels. In one embodiment of the present invention, whether there are supports or extensions, depressions such as grooves, valleys, indentations or channels or one or more groups of depressions can extend substantially to the entire length or width of the polymer core in any direction. For example, the depressions can extend in the longitudinal direction, in the transverse direction or in the cross direction. Not all depressions can be matched with the member, and not all depressions extend substantially along the entire length or width of the core. Similarly, in this embodiment, the member (if matched with a depression extending substantially along the entire length or width of the core) can substantially extend the entire length of the load-bearing structure. In another embodiment, when there are supports or extensions, depressions such as grooves, valleys, indentations or channels or one or more groups of depressions can be present between the supports. In this embodiment, when depressions such as grooves, valleys, indentations or channels or one or more groups of depressions are matched with the member, they can also extend between the supports. In other embodiments, not all depressions may be matched with the member, and some depressions may also extend substantially along the entire length or width of the core. Also, when the member is matched with the depressions, it may be matched before the polymer core is covered with a thermoplastic film or sheet or the polymer core is combined with the thermoplastic film or sheet, as described above. In another embodiment, in some examples, at least one depression such as a groove, a valley, an indentation or a channel may also be present on the side of the support or extension. In this embodiment, a depression or multiple groups of depressions such as a groove, a valley, an indentation or a channel may also extend to the side of the support, and when the member is matched with the depressions, it may be matched before the polymer core is covered with a thermoplastic film or sheet or the polymer core is combined with the thermoplastic film or sheet. In addition, in this embodiment, some depressions may be present in the support, rather than between the supports, and not all depressions may be matched with the member. In another embodiment, when supports or extensions are present, some of the depressions or some of the groups of depressions, such as grooves, valleys, indentations or channels, may be present between supports or extensions, and if they are mated with a member, the member may also be present between supports or extensions. Other depressions or other groups of depressions may extend substantially the entire length or width of the polymer core, or in any cross-direction, for example, the depressions may extend longitudinally, transversely, or in a cross-direction, etc. In this embodiment, if a member is mated with the depressions, the member mating with the depressions may extend the entire length of the load-bearing structure. As described above, not all depressions may be mated, and there may be any combination of mated depressions and unmated depressions.In another embodiment, in some examples, at least one depression, such as a groove, valley, indentation or channel or multiple groups of depressions may also be present on the side of the support. In this embodiment, the groove, valley, indentation or channel may also extend to the side of the support, and when the member is matched with the depression extending to the side of the support, it can be matched before the polymer core is covered with a thermoplastic film or sheet or the polymer core is combined with the thermoplastic film or sheet, as described above. Other depressions may extend substantially the entire length or width of the polymer core, or extend in any cross direction, for example, the depression may extend longitudinally, transversely or in a cross direction, etc. In this embodiment, if the member is matched with the depression, the member matched with the depression may extend the entire length of the load-bearing structure. As described above, not all depressions may be matched, and there may be any combination of matched depressions and unmatched depressions.

[0040] In one embodiment of the invention, the bottom side of the core may include depressions, which may be long depressions and / or short depressions. The long depressions may extend substantially along the length or width of the core, only two or no more than three such long depressions may be matched with the corresponding components, and all other depressions remain as depressions in the final processed load-bearing structure. The size of the long depressions may be, for example, 75%, or, for example, 80%, or even, for example, 85% of the length or width of the core.

[0041] In another embodiment of the present invention, the bottom side of the core may include a depression, which may be a long depression and / or a short depression. The long depression may extend substantially along the length or width of the core. There may be multiple supports or extensions, and multiple supports or extensions may also extend substantially vertically from the bottom side of the core. Only two or no more than three such long depressions and depressions extending between the extensions or supports may be matched with the corresponding components, and all other depressions remain as depressions in the final processed load-bearing structure. The extension or support may include a solid interior or a hollow interior or a partially hollow interior. The hollow interior or the partially hollow interior may be matched with the corresponding components so that the bottom of the extension or support may have a generally flat feel or appearance after being combined or linked with a polymeric sheet or film to form a load-bearing structure, substantially covering up any indication that it is hollow after matching, as discussed above. The size of the long depression may be, for example, 75% of the length or width of the core, or, for example, 80%, or even, for example, 85%.

[0042] In another exemplary embodiment, the load bearing structure of the present invention may be formed of a lightweight polymer core covered by or combined with one or more polymer sheets or films, wherein the extensions extend from the bottom of the polymer core. The load bearing capacity may be further improved, such as the ability to transport heavier objects, or to have increased rigidity or strength without making the load bearing structure heavier, by providing the core with at least one depression such as a groove, valley, indentation or channel on its underside and at least one corresponding member cooperating with one of the at least one groove, valley, indentation or channel, wherein at least one depression also extends downwardly from the sides of each extension and extends upwardly from the sides through the bottom and then through the entire length or width of the load bearing structure.

[0043] In one aspect, the at least one depression may include one or more depressions spaced apart from one another on the underside of the polymer core. If more than one depression is present, not all depressions may have the same length, shape, or depth. In one embodiment, a corresponding member may mate with all depressions present. In another embodiment, not all depressions (if more than one is present) mate with a corresponding member.

[0044] Each of the components (if there is more than one) may include an elevated central portion, which may have a cross-section of any shape, for example, a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section or the like, which may or may not have flat portions extending from the lower portion of both sides of the central portion, for example, wing-shaped components. When mated, the central portion may be substantially filled in one of at least one groove, valley, indentation or channel of various shapes. The central portion and wing-shaped components, if present, may be directly or indirectly adhered to or bonded to the lower side and extension of the polymer core. In one embodiment, the component may cover or bond to the polymer core before the polymer core is covered by one or more polymer sheets or films or bonded to one or more polymer sheets or films. In another embodiment, the component may cover or bond to the load-bearing structure after the polymer core is covered by one or more polymer sheets or films or bonded to one or more polymer sheets or films.

[0045] In another aspect, at least one depression may include one or more groups of closely spaced parallel depressions, such as grooves, valleys, indentations, or channels. The depressions within a group may or may not have the same length, shape, or depth. The internal spacing between a group of depressions may be smaller than the spacing between adjacent groups (if any). In other words, the spacing of parallel depressions within a group may be smaller than the spacing between two separate grooves (if any) that are not within a group. In one embodiment, the corresponding member may be mated with all depressions that exist. In another embodiment, not all groups of depressions (if more than one group exists) are mated with the corresponding member. Not all depressions within a group are mated with the member.

[0046] The corresponding member for each depression, whether or not the depressions are part of a group, may include at least one raised central portion for each depression. The member for a group of depressions (if all depressions in a group are mated with raised portions) may include at least two raised central portions, which may have a cross-section of any shape or combination of shapes, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section, or the like, with or without a flat portion, such as a wing-shaped member, extending from the lower portion on either side of the raised central portion. If there is one or more than one group, the raised portion may have a cross-section of any shape or combination of shapes, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section, or the like, with or without a flat portion, such as a wing-shaped member, extending from the lower portion on either side of an elevated central portion. When mated, the raised central portion may be substantially inserted into one of at least one correspondingly shaped groove, valley, indentation, or channel. The raised portions and wings, if present, may be adhered or bonded directly or indirectly to the underside of the polymer core. In one embodiment, the member may cover or bond to the polymer core before covering or bonding the polymer core with one or more polymer sheets or films. In another embodiment, the member may cover or bond to the load-bearing structure after covering or bonding the polymer core with one or more polymer sheets or films.

[0047] As described above, the length of the member can be customized using any method. It can be manufactured in a desired length or it can be manufactured in batches and then cut to fit the length of the depression, such as the groove, valley or channel to be matched. In one embodiment of the invention, the groove, valley, indentation or channel can extend substantially to the entire length or width of the polymer core in any cross direction. For example, the depression can extend longitudinally, laterally or in a cross direction. Likewise, in this embodiment, the member can extend substantially to the entire length or width of the load-bearing structure. In another embodiment, some or a plurality of groups of depressions, such as grooves, valleys, indentations or channels, may be present between the supports or extensions, and if these depressions are matched with a member, the member may also extend between the supports and the extensions; and other depressions may also extend substantially along the entire length or width of the polymer core and extend below the side of the supports or extensions and above the other side of the supports or extensions through the bottom, for example, the depressions may extend longitudinally, transversely or crosswise, and similarly, in this embodiment, if the member is matched with the depressions, the member that can be matched with the depressions may extend along the entire length or width of the load-bearing structure. In this embodiment, when the member is matched with the depressions, the matching may be performed before the polymer core is covered with a thermoplastic film or sheet or the polymer core is combined with the thermoplastic film or sheet, as described above.

[0048] The extension may comprise a plurality of components, such as at least 4, or more such as at least 6, and even more such as at least 9. The group of components may be evenly spaced or unevenly spaced from each other, as long as they can be easily loaded and unloaded using, for example, a forklift.

[0049] In one embodiment, a plurality of reinforcing extensions may be uniformly spaced apart and extend in a substantially vertical direction from the bottom of the polymer core. In another embodiment, a plurality of reinforcing extensions may be non-uniformly spaced apart and extend in a substantially vertical direction from the bottom of the polymer core.

[0050] According to one aspect of any of the various embodiments, the member may be a solid structure. According to another aspect of any of the various embodiments, the member may include any degree of internal hollowness in the central portion (such as a dome-shaped portion) to reduce the weight of the resulting load-bearing structure. Surprisingly, the internal hollow central portion does not impair the improvement in the capacity of the load-bearing structure obtained thereby, such as the ability to transport heavier objects.

[0051] The wing-like member, if present, may have a small thickness so that after the member is fitted together with the groove or the like, and before or after the polymer core is bonded to or covered with a thermoplastic sheet or film, the resulting combination may be substantially flush with the remainder of the underside of the polymer core where the member is not present. Generally, whether the center portion is solid or hollowed out to any extent, the underside of the resulting load-bearing structure may have a relatively smooth feel with very little visible bulge or protuberance. A load-bearing structure having at least one groove on the underside of a polymer core and the at least one groove bonded to or covered by at least one member has improved properties, such as being able to transport more weight than a load-bearing structure without the groove.

[0052] The wing members, if present, can help adhere or bond the member to the underside of the load-bearing structure, or to the core or film or sheet, depending on whether the member is attached before or after covering or bonding to the core with the sheet or film. The wing members can also be tapered towards the ends to provide a smoother transition of the member to the underside of the core.

[0053] In one embodiment, when a wing-like member is present, the configuration of the depression, such as a valley, indentation, or channel, can be the same as the configuration of the depression when the wing-like member is not present. The wing-like member can be located on top of the underside of the load-bearing structure, or on top of the core or cover film or cover sheet. After bonding or bonding, the bottom side of the load-bearing structure can present a substantially smooth feel or appearance, as described above. In another embodiment, when a wing-like member is present, the depression (e.g., valley, indentation, or channel) can be modified, such as dented, to accommodate the wing-like member so that the member with the wing-like member can be completely flush with the bottom side. After bonding or bonding, the bottom side of the load-bearing structure can present a substantially smooth feel or appearance.

[0054] The extension may have a cavity in part or substantially all of the interior. The cavity portion may be bottomed to form a depression such as a valley, indentation or channel on the bottom surface of the extension, and the cavity portion may cooperate with a similar component as described above so that after being combined or bonded with the component, the bottom of the extension presents a substantially smooth feel or appearance without any signs that it is a cavity. The cavity extension also helps reduce the weight of the load-bearing structure.

[0055] Although the interior of the support or extension is a cavity, when the polymer core is combined with the thermoplastic film or sheet, that is, during the thermoforming process, the cooperation of the extension with the corresponding component can present an exterior that is substantially similar to a polymer core with a solid extension. As mentioned above, the cooperation of the extension with the component can also occur after the bonding process.

[0056] The hollowing extension can be performed when the core is manufactured or after the core is manufactured. It may be easier and save time to build the cavity extension during manufacturing.

[0057] In one embodiment, the hollowing out can occur over substantially the entire length of the extension and can be shaped as a corresponding member to fit substantially the entire recess. In one aspect, the member can be hollowed out as described above. In another aspect, the member can be solid. In another embodiment, the recess or hollowing out of the support or extension can be partial.

[0058] The interior of the cavity may also be tapered. In one aspect, the taper may be toward the bottom of the support or extension. In another aspect, the taper may be toward the top of the support or extension. A taper toward the top of the support or extension may make it easier to fit with the member, and the member may substantially fill the cavity space of the support or extension, or to any desired extent. A taper toward the bottom may be possible, but the extension may not substantially fill the space inside the cavity, and the member may not substantially correspond to the shape of the recess, making it easier to insert the member into the recess.

[0059] When tapered, the member may also be tapered accordingly to better fit the depression. As described above, the member may also include a hollow center portion to minimize the weight of the entire construction. At the same time, at least one depression such as a groove, valley or channel located on the underside of the core and extending to the lower side of each extension and extending through its bottom to the upper side thereof and then extending through the entire length or width of the load-bearing structure, and at least one corresponding member that cooperates with one of the at least one groove, valley, indentation or channel can further enhance the extension and its connection to the bottom of the polymer core.

[0060] The hollow interior of the extension and the member also help to reduce the weight of the load-bearing structure without substantially affecting the load-bearing performance of the structure. In fact, the load-bearing performance may be enhanced.

[0061] The hollowed-out extensions and members not only help reduce the weight of the load-bearing structure, but also do not substantially affect the load-bearing performance of the structure. In fact, the load-bearing performance can be enhanced. For example, at least one depression such as a groove, valley or channel located on the underside of the core and extending toward the lower side of each hollow extension and extending through its bottom to the upper side thereof through the entire length or width of the load-bearing structure, and at least one corresponding member that cooperates with one of the at least one groove, valley, indentation or channel, can further enhance the hollow extension and its connection to the bottom of the polymer core, whether or not the connection is formed integrally.

[0062] In one aspect of any of the above embodiments, at least one depression (e.g., groove, valley, indentation, or channel) of one or more rows or groups of rows located on the lower side of the core may exist along one direction on the lower side of the core and at least one corresponding component that cooperates with one of the at least one groove, valley, indentation, or channel. In another aspect, at least one depression (e.g., groove, valley, indentation, or channel) of one or more rows or groups of rows may exist along multiple directions on the lower side of the core and at least one corresponding component that cooperates with one of the at least one groove, valley, indentation, or channel.

[0063] The member may be cast or molded, for example, extrusion molded or injection molded. The raw material may be a sheet or film that can be molded or cast into the desired member. The raw material may also be in pellet form, powder form, or any form that can be easily transported to an extruder for extrusion molding or injection molding. The molding process employed may form a solid member or a member having a hollow center without further processing. The wing member, if present, may be integrally formed with the remainder of the member.

[0064] The member may be made of any polymer (e.g., a polymer that can be formed into a film by extrusion, injection molding, or any other film-forming method). The polymer may be similar or identical to a polymer sheet or film that covers or is bonded to a polymer core when making a load-bearing structure. For some embodiments, the member may include a metal film.

[0065] The shape of the core generally determines the shape of the load-bearing structure. As described above, the core may include a top side and a bottom side, and a width portion connecting the top side and the bottom side, and in some cases, may or may not include multiple extensions extending from the bottom side of the core. When multiple extensions are present, the multiple extensions form a support for the load-bearing structure. The bottom side and the extensions (if present) may be covered by or combined with a polymer sheet or film, if only one polymer sheet or film is used, the sheet or film extends to wrap the bottom surface, the extension (if present) and the entire thickness of the width and at least a portion of the top, if two polymer sheets or films are used to cover the top surface, the entire thickness of the width and the bottom surface and may include an overlap of the sheets around the width, one sheet or film may extend to cover one side and at least a portion of the thickness of the width, and the second sheet or film may cover the rest of the exposed surface. To a large extent, one or more polymer sheets are bonded to the core, or if one polymer sheet is used, substantially almost the entire sheet is bonded to the core. The bonding can be achieved by heating and / or pressing. As mentioned above, the structure can be assembled before or after one or more sheets are combined or bonded to the core.

[0066] When the core is covered by a polymer sheet that covers the bottom, the entire thickness of the width, and at least a portion of the top, the outer edge portion of the polymer sheet on the top surface of the core can be additionally sealed to a portion of the top surface of the core by using a sealing tape, a sealing chemical composition, a sealing liquid, or a mechanical and / or heat sealing device (and can include, for example, ultrasonic heat sealing devices). The sealing tape, sealing liquid, sealing chemical composition, or mechanical and / or heat sealing device helps to seal the edge portion to the top surface of the core, although it may also help to seal the rest of the sheet to the bottom of the core, the extension (if present), the entire thickness of the width, and a portion of the top surface of the core, but it is not necessary.

[0067] When the core is covered by two polymer sheets, the bottom sheet covers the bottom surface of the core, the extension (if present) and at least a portion of the thickness of the width of the core, and the top sheet covers the top surface of the core, and at least a portion of the thickness of the width, forming a small overlap of the first sheet and the second sheet around the width, if necessary. At least a portion of the overlap of the first sheet and the second sheet (for example, at least a portion of the overlap near the edge of one or more sheets) can be securely sealed together by a sealing member, for example, by using a sealing tape, a sealing solvent, a sealing compound or a mechanical and / or heat seal, and can include, for example, an ultrasonic heat sealer. The sealing tape, sealing solvent, sealing compound or a mechanical and / or heat seal, and can include, for example, an ultrasonic heat sealer, is used to assist in sealing the edges of the overlapping portions of the first and second sheets, and can also assist in sealing the remaining portions of the first and second sheets to the core and assist in sealing the remaining portions of the first and second sheets to each other.

[0068] The edge of the sheet or film may be the outer edge of the sheet or film, or the edge of a fold when some hem is present.

[0069] Typically, the polymer core can be made of a foam material such as polystyrene foam, polyurethane foam, vinyl foam, acrylic foam or phenol foam. The polymer foam can typically be a closed cell foam. The closed cell foam can also provide a certain surface roughness to facilitate its bonding to the component and / or polymer film or sheet. The density of the foam can be varied, usually without a significant effect on the load-bearing capacity of the load-bearing structure. However, it is generally believed that increasing the density of the polymer core (or foam) can affect the strength of the resulting load-bearing structure, that is, the higher the density of the core, the higher the strength of the load-bearing structure. Therefore, using a higher density foam, a polymer core of smaller thickness can be obtained, resulting in a smaller thickness of the width portion without substantially affecting the load-bearing capacity of the resulting load-bearing structure. The load-bearing structure may or may not include an extension. In some cases, a load-bearing structure with a shorter profile may be advantageous when it is advantageous to transport goods that are limited in space in addition to weight.

[0070] A load bearing structure with a smaller thickness or lower profile that improves load bearing performance can also be achieved using a low density core with depressions or indentations and a corresponding member that fits together. The load bearing structure may or may not include extensions. Thus, the member can improve the performance of a lower density core without having to use a higher density core for a lower profile load bearing structure.

[0071] The polymer sheet or film can be made of any film-forming material that can impart strength to the core material, such as, but not limited to, high impact polystyrene; polyolefins such as polypropylene, low density polyethylene, high density polyethylene, polyethylene and polybutylene; polycarbonate; acrylonitrile-butadiene-styrene; polyacrylonitrile; polyphenylene ether; polyphenylene ether alloys with high impact polystyrene (HIPS); polyesters such as PET (polyethylene terephthalate), APET and PETG; lead-free polyvinyl chloride; copolyester / polycarbonate; or copolymers of any of the above polymers; or composite HIPS structures.

[0072] Typically, the covering film or sheet may not contribute to the overall thickness of the load-bearing structure. However, the higher the strength of the polymer film or sheet, the thinner the covering sheet or film may be without sacrificing the overall strength of the load-bearing structure. The component may be made of the above-mentioned polymers, as described above. For components made of a polymer substantially the same as or similar to the covering film or sheet, the adhesion or bonding between the component and the covering film may be better than with a different polymer, regardless of whether the component is applied before or after covering the polymer core with the polymer sheet or film.

[0073] Typically, the edges of the load-bearing structure may include a polymer core covered by a polymer sheet or film, as described above. In some embodiments, additional components may be present around some of the edges at intervals or continuously. The components may generally improve or increase the strength of the edges of the load-bearing structure, thereby minimizing wear or damage during use or repeated use.

[0074] Typically, the member may include additional portions to improve its strength and sometimes increase the weight of the load bearing structure. The member may include edge protectors, as described below. The edge protectors may be present on the core or on the polymer sheets. When present on the core, the polymer sheets or films may or may not be bonded or adhered to the edge protectors. If the edge protectors are not bonded or adhered to one or more polymer sheets, the outer edges of the sheets may be bonded to the edge protectors via a sealing member. If the edge protectors are bonded or adhered to one or more polymer sheets, the outer edges of the sheets may also be bonded to the edge protectors via a sealing member.

[0075] In these embodiments, the load bearing structure may be reinforced with some edge protectors. When cargo loaded on the structure is held down by cargo retaining items, such as straps, tiedowns, cables, ropes and / or other items to help secure the cargo, especially during transportation, edge protectors may be needed to minimize movement. When used, the bottom edge and portion of the width near the bottom edge of the load bearing structure generally bear substantially all of the force of, for example, the straps. In one embodiment, the protectors may be present at intervals at predetermined locations on the load bearing structure where reinforcements may be required. Tiedowns may also be used at these same predetermined locations to help secure the cargo to minimize movement. In another embodiment, the edge protectors may be present continuously around the perimeter of the structure. In another embodiment, the edge protectors may be present continuously or at intervals at the bottom and top edges. According to one embodiment, the edge protectors may have an L-shaped cross-section and may be present at intervals or continuously around at least a portion of the bottom and a portion of the width portion of the core in a manner that wraps around a portion of the bottom near the outer edge to wrap around the edge and extends to cover a portion of the width portion near the bottom. According to another embodiment, the edge protector may have a substantially C-shaped cross section with a right-angle edge, and may be spaced or continuously present around the bottom, width portion, and a portion of the top of the core, in a manner of wrapping a portion of the bottom surface near the outer edge to wrap around the edge and extending to cover the width portion and a portion of the top surface near the width portion. According to yet another embodiment, the edge protectors appear in pairs, each having a substantially L-shaped cross section, and may be spaced or continuously present around the bottom, width portion, and a portion of the top of the core, in a manner of one of the pair wrapping a portion of the bottom surface near the outer edge to wrap around a portion of the edge and at least a portion of the width portion near the bottom side; and the other of the pair extending to cover a portion on the width portion near the top surface and a portion of the top surface adjacent to the width portion.

[0076] In one embodiment, edge protectors may be present on the core prior to covering the core with the polymer sheet. In one aspect, the core may be indented to accommodate the one or more protectors so that the one or more protectors are flush with the rest of the core, so the sheet may cover the core with the one or more protectors as if the protectors were not present. In another aspect, the core may be indented but not enough to accommodate the full thickness of the one or more protectors, so after covering with the sheet, there may be a slight bump where the protectors appear. The slight bump serves as an indicator or how to position the retaining device. In another embodiment, the protectors may be added after the core is covered with the one or more polymer sheets, and may be flush with the rest of the load-bearing structure or extend out to form a slight bump.

[0077] When the guard is added before covering the core with the polymer sheet, the core may be indented (as described above) and the guard may not be easily discernible after covering the core with the polymer sheet. In examples similar to these, some guide members may be present on the load-bearing structure to better locate retaining members, such as straps for cargo securing. The guide members may include markings, slight bumps, protrusions or ridges to better define strap locations.

[0078] The guard may be constructed of any polymer, or metallic material, or combination thereof, that can be easily molded or cast into the desired shape and that is rigid (substantially rigid) or has edges of sufficient strength. In one embodiment, when the guard is present prior to covering the core with one or more polymer sheets, the guard may be made of a material that is the same as or has similar bonding properties as the sheets to assist in bonding the guard to the sheets and / or core at the sheet-to-core bonding temperature. However, as described above, guards made of other materials may still be bonded to the outer edges of the sheets using a sealing member. In another embodiment, when the guard is added to the load-bearing structure after one or more sheets are bonded to the core, any material may be used for the guard.

[0079] To help hold the guard to the core before or during bonding, a tacky material (e.g., an adhesive or double-sided tape) may also be used. Examples of adhesives may include pressure sensitive adhesives, such as hot melt pressure sensitive adhesives or non-hot melt pressure sensitive adhesives. Examples of double-sided tapes may include double-sided pressure sensitive adhesive tapes, such as double-sided hot melt pressure sensitive adhesive tapes or double-sided non-hot melt pressure sensitive adhesive tapes. The thickness of the adhesive or tape may be so thin that it does not substantially contribute to the thickness of the edge guard. In some embodiments, the adhesive or tape may be substantially melted during the bonding process.

[0080] When the edge protectors are present after the bonding process, a structural adhesive such as those used in edge sealing described above or below may be used to secure the edge protectors so that the edge protectors do not fall off or move during and after bundling to secure the cargo.

[0081] The guard can be of any thickness as long as it provides the desired reinforcement to the edges. Some materials have higher stiffness than others, so a thinner guard may be sufficiently stiff. Those more flexible, thicker components may be required to provide sufficient stiffness or strength to withstand the forces of any cargo securing devices such as straps.

[0082] The edge protector may be located anywhere on the load-bearing structure, including where the member is located. In one embodiment, both the member and the protector may be attached before the core is bonded to the polymer sheet or film or the core is covered with a polymer sheet or film. In another embodiment, both the member and the protector may be attached after the core is bonded to the polymer sheet or film or the core is covered with a polymer sheet or film. In yet another embodiment, the member may be attached before the core is bonded to the polymer sheet or film or the core is covered with a polymer sheet or film, and the protector may be attached thereafter. In yet another embodiment, the member may be attached after the core is bonded to the polymer sheet or film or the core is covered with a polymer sheet or film, and the protector may be attached thereafter.

[0083] The edge protectors can be manufactured by molding or casting. In one embodiment, the edge protectors can be manufactured in batches and then cut to size. In another embodiment, the edge protectors can be manufactured individually to one or more sizes.

[0084] It is often desirable to improve the weight of a load bearing structure while improving the strength of an edge. The present invention includes components that may include a portion of a roughened edge, such as a notched edge, such as a serrated edge. The roughened edge may be integral to the polymer core. This is in contrast to the edge protectors described above, which are not integral to the polymer core, but are an add-on to the polymer core.

[0085] The roughened edge portion may be present on the core and the shape may be retained after bonding with one or more polymer sheets. Typically, the roughened edge portion may be formed on the core during the process of forming the core or may be introduced after the core is manufactured.

[0086] In one embodiment, the roughened edge portion may be present on at least the bottom edge of the width portion connecting the top side and the bottom side. In another embodiment, the roughened edge portion may be present anywhere along the width portion of the core. As described above, the roughened edge portion may be present continuously or intermittently along the width portion connecting the top side and the bottom side. Although the core with the roughened edge portion uses less material when the roughened edge has some recessed areas on the edge of the core, the edge of the resulting core is surprisingly stronger than a core with uniform edges all around.

[0087] The roughened edge portion may include a notched edge portion, for example, a serrated structure portion having teeth of any length and shape, or a similar structure. In one embodiment, the ends of the teeth may be substantially smooth. In another embodiment, the ends of the teeth may be slightly pointed. Each tooth may have a length approximately equal to the thickness of the width portion of the edge, or a length approximately equal to half the thickness of the width portion of the edge, or the length of each tooth may be any length between half the length and the above full length. As described above, the roughened edge portion does not extend further from the side of the core than the unroughened edge portion.

[0088] The roughened edge portion may extend along the edge of the core for a length, occasionally interrupted by a non-roughened edge portion. In one embodiment, the roughened edge portion may exist along two parallel sides of the core. In another embodiment, the roughened portion may exist along all sides of the core.

[0089] When present along one side of the core, the roughened portion may be present continuously or discontinuously along the side.

[0090] As mentioned above, the edge seals described above may be used whether the load-bearing structure has or does not have edge protectors or roughened edges.

[0091] As described above, the bonding between the core and one or more polymer sheets, with or without the member or guard, can be achieved by applying heat and pressure. In some embodiments, the bonding between the core and the thermoplastic sheet or film and the bonding between the polymer sheets or films generally includes sufficient bonding of the portion of the core adjacent its surface to the portion of the polymer sheet adjacent its surface, or sufficient bonding of the portion of one polymer sheet adjacent its surface to the portion of the second polymer sheet adjacent its surface, so that any attempt to separate the two components will generally not result in complete separation of the components, but may result in some adhesion failure of adjacent interfaces. The bonding process used to make this usually occurs at a relatively high temperature, for example, a temperature sufficient to soften the polymer material. The temperature also depends on the type of polymer used to produce one or more sheets.

[0092] When the polymer core is covered by a polymer sheet, the edge of the polymer sheet is bonded to the surface of the core by heating and pressure. When the core is covered by two polymer films and the edges of the two films overlap each other, the edge of one sheet can be bonded to the surface of the second sheet by heating and pressure. Although the bonding process completely bonds the sheet to the core or the sheet to the sheet, it is difficult to perfectly bond the edges so that no adhesive or adhesive failure occurs at the interface due to defects in the bonding, for example. In addition, more such failures can usually occur at the edges, which is also attributed to repeated gripping of the edges.

[0093] The member and the core or the member and the sheet or film can be bonded using sufficiently high heat or sufficiently high heat and pressure to obtain a substantially integral load-bearing structure. The underside of the load-bearing structure having the present member is substantially smooth with minimal protrusions as previously described.

[0094] When the polymer core is covered by a polymer sheet or film, any unbonded portion of the film can be trimmed after the bonding process. When the core is covered with two polymer films and the edges of the two films overlap each other, any unbonded portion of the second film can be trimmed and removed. However, general trimming may not be effective enough to cut off the unbonded portion required completely. Some parts of the unbonded edge remain on the load-bearing structure. For example, for two polymer films to be bonded at the edge, the edge portion that is not firmly bonded can be trimmed to as close to the bonding line as possible, but there is no excessive cost or consideration that may not be able to trim all unbonded portions. For a film to be bonded to the core, it is equally difficult to trim the unbonded portion. In addition, although the core and the polymer film or the two polymer films are well bonded, as mentioned above, for example, it may be difficult to fully bond the edge so that no trimming is required, and some defects or adhesion failures in the adhesive or adhesion at the interface caused by, for example, repeated gripping of the edge also appear more usually at the edge.

[0095] For embodiments where the polymer film or sheet has a folded edge, the fold is the edge, and while trimming may not be performed, some imperfections may occur in the folded edge bonding.

[0096] When one or more faces are bonded together, the more smooth or flatter these one or more faces are, the more perfect bonding can be formed with less defect.Under the situation that do not wish to be limited by theory, although infer that one or more faces of core and / or polymer sheet are made as far as possible evenly smooth, these one or more faces of core and / or polymer sheet can still be uneven, and therefore, may have defect in bonding, unless take expensive or special step, so that these one or more faces are smooth.After finishing making core and / or sheet material, the easy way of making surface smooth can be that surface is heated to the temperature high enough to make surface melting, so that molten material can flow, to cover the defect that makes these one and / or multiple faces uneven or not smooth.The processing of high temperature like this may unnecessarily destroy core and / or sheet material.

[0097] When there is such defect or unevenness on one or more surfaces of the core or sheet leaving the edge, moisture, dust and / or products left over from previous goods and bacteria grown on moisture, dust or products left over from previous goods cannot accumulate because these surfaces are exposed to moisture, dust and / or products left over from previous goods and bacteria grown on moisture, dust or products left over from previous goods. However, any such defect at the edge is more likely to attract moisture, dust and / or products left over from previous goods, bacteria grown by moisture, dust or products left over and moisture, dust and / or products left over and bacteria may be more likely to accumulate around the edge, and once left over on the product, it becomes more difficult to clean it once because the accumulation is more or less hidden. This may cause product contamination or at least cross contamination, and if the structure is reused for goods (such as different food types, such as poultry, fresh vegetables, fresh fruits) or even the same type of products that are different from previous goods, it is dangerous to perform strong purification and also cause the load-bearing surface to be non-reusable or reused. Even new load-bearing structures that are not covered or properly stored before use may be susceptible to contamination or infection. Therefore, eliminating contamination or susceptibility to contamination in these hidden areas is important for cargo such as food, pharmaceuticals, electronics, or any product with exposed surfaces that could be contaminated.

[0098] In an exemplary embodiment, a sealing liquid can be used. After the core is covered and bonded by one or more sheets, the liquid can be used for the interface between the core and the sheet or the overlapping edges of multiple sheets. The sealing liquid can be any liquid that can soften or dissolve the polymer material (or multiple polymer materials) at the interface between the sheet and the core or between multiple sheets to a certain extent to promote the firm bonding of the components at the edge. It is expected that the sealing liquid can be distributed and applied in a controlled manner or dosage to minimize overflow or dripping or waste of liquid or minimize excessive dissolution of material on the interface, for example, by using a syringe-type dispenser or other metering device. Regardless of the dispensing device, the front tip of the dispensing device, such as a hole, has a small cross-section, such as just enough for the liquid to be dispensed. The sealing liquid can be active at room temperature. By applying the liquid to the outer edge of one or more sheets or to the core to be sealed, the sealing liquid can also be applied before the sheet is bonded to the core or another sheet.

[0099] In another exemplary embodiment, a sealing tape can be used. Before one or more sheets are bonded to the core, the tape can be used on the edge of one of the one or more sheets or the core (when using a sheet) so that the high temperature used to bond the one or more sheets can also activate the adhesive used to bond the tape to the core or sheet at the edge. The tape can include a non-sticky or solid heat-activated adhesive (such as a hot melt adhesive, a heat-curing adhesive, or a reactive adhesive) on one side, and a contact or tacky adhesive on the other side. The contact or tacky adhesive can be covered with a liner before use, and the tape can be tensioned into a roll during storage. When applied to sheets, the liner can first be separated from the contact or tacky adhesive side and bonded to at least a portion of the top surface of the core or the edge of the sheet (if one sheet is used or vice versa), or bonded to at least a portion of one side of the second sheet to be bonded to the first sheet (if two sheets are used or vice versa), or separated essentially simultaneously, and the contact or tacky adhesive is applied to one side of the sheet to be bonded to at least a portion of the top surface of the core or the edge of the sheet (if one sheet is used), or to at least a portion of the second sheet to be bonded to the first sheet (if two sheets are used or vice versa), so that the heat-activated adhesive side can be exposed before being bonded to the core or sheet, or the first sheet or the second sheet.

[0100] Sealing tape can include a heat activated adhesive sheet coated with a contact or tacky adhesive on one side, as described above. In one embodiment, the heat activated adhesive can be applied to the liner to form a non-tacky adhesive sheet when cooled or dried. On the one hand, the adhesive can be applied to the liner in solution form, and after the solution evaporates, the adhesive layer can form a non-tacky adhesive sheet. On the other hand, the adhesive can be extrusion coated to the liner and cooled to a non-tacky adhesive sheet. In another embodiment, the heat activated adhesive can be any film form that can be cast or extruded and cooled to a non-tacky adhesive sheet, such as a hot melt adhesive.

[0101] Heat activated adhesive can be applied on the exposed surface by contact or viscous adhesive, if heat activated adhesive appears on the backing plate, or if there is no liner on either side. Any suitable coating technology can be used to apply contact or viscous adhesive, including but not limited to solvent coating, extrusion coating or screen printing with a usually dense array pattern of dots or micro dots. The thickness of contact or viscous adhesive and heat activated adhesive can vary, but they can usually be thin enough to create an edge that is less significant after edge bonding, which can in turn reduce the tendency to separate. Contact or viscous adhesive and heat activated adhesive can be selected to form a good combination between the core and the edge of the polymer sheet or between the edge of the first polymer sheet and the second polymer sheet. Contact or viscous adhesive can be selected with good adhesive properties to form a good combination between it and the hot melt adhesive layer to reduce the adhesive failure on their interface. Adhesive tape can also help to establish a smoother transition at the exposed edge at the interface, and can also help to reduce the tendency to separate at the edge. The heat activated adhesive may be any hot melt adhesive, heat curing adhesive, reactive adhesive, etc., that is activated at about the same temperature as the bonding temperature of the polymer layer and the core to form a good bond at the edges, as described above.

[0102] In application, separation of the liner from the adhesive layer can be achieved manually by peeling the liner from the core or polymer sheet prior to use, or by using a tape dispenser simultaneously or nearly simultaneously with the application of the contact or tacky adhesive to the polymer sheet, which tape dispenser can automatically separate the liner from the tacky adhesive during use.

[0103] In other embodiments, the tape may also be applied to the edges after one or more polymer sheets have been bonded so that the tape appears on the outside. In these embodiments, the adhesive may be a pressure-sensitive or heat-sensitive adhesive on only one side, coated on the back.

[0104] In other embodiments, one side of the tape may include a heat activated adhesive while the other side may include a pressure sensitive and heat sensitive adhesive such that the tape is secured by pressure prior to heat activation during the bonding process.

[0105] In a further exemplary embodiment, a chemical sealing component can be used. When a polymer sheet is used, the edge of the sheet can be further bonded to the polymer core, or when two polymer sheets are used, bonded to the overlapping area of ​​the first and second layers of the chemical sealing component that can be liquid before use. The chemical component can be a liquid or slurry that can be activated by drying or at the bonding temperature during the bonding process. The slurry can include a mixture of liquids with dispersed particles of the polymer sheet. The liquid chemical sealing component can be used in its natural liquid form, slurry or semi-solid form, or in a treated solid form. And the liquid in the natural form can be applied in a manner similar to the above-mentioned sealing liquid. The treated slurry can be applied before or after the bonding process or distributed from a box (such as the above-mentioned plastic squeeze bottle, but its distribution end has a larger opening) to the edge of the polymer sheet between the core and the sheet. When used before the bonding process, the component can help bond the sheet to the core or bond the sheet to the sheet, and the liquid and particles can be activated during the bonding process. When the treated chemical sealing component is in solid form, it can include small encapsulated particles that encapsulate the liquid. Application of solid form may include using a device for sprinkling treated chemical components onto the edges of the core and one or more polymer sheets prior to the bonding process. In either form, if desired, the chemical sealing component may be activated during the bonding process of bonding the polymer core to the one or more polymer sheets.

[0106] The treating material used to form the treated solid form of the chemical seal component allows it to flow freely, ie, the treated forms do not adhere to each other but can adhere adequately to a core or sheet, even temporarily prior to a bonding process.

[0107] Examples of slurry combinations may include a mixture of the above-described sealing liquid mixed with a heat-activated polymer powder, such as mixed with the same or similar powdered polymer material used in the manufacture of the polymer sheet. For example, when the polymer sheet is made of high impact polystyrene, then the powder is powdered polystyrene. The sealing liquid may be relatively non-volatile, such that the liquid does not substantially evaporate prior to the bonding process between the sheet and the core and / or between the sheets.

[0108] As described in more detail below, the chemical sealing composition may also include a self-recovering and / or self-healing composition. The self-recovering and / or self-healing composition may also be present in any other sealing component.

[0109] In yet another exemplary embodiment, the edges can be sealed by mechanical and / or heat sealing means, such as ultrasonic heat sealing means. For example, ultrasonic energy can be generated using, for example, an ultrasonic horn and / or an ultrasonic welder. The ultrasonic energy level can be selected to affect but not distort the edges during bonding.

[0110] In some embodiments, as the first and second polymer sheets are bonded to the polymer core, they can be partially folded over each other, and the folded areas can be subjected to heat, pressure, and / or vacuum to create a sealed bond area. Excess material of the polymer sheets can be trimmed off.

[0111] In one embodiment, the polymer sheet or film layer may include an antimicrobial agent having a certain surface activity. In another embodiment, an antimicrobial coating having a certain surface activity may be applied to at least one of the exposed surfaces of the load-bearing structure, whether or not the surface is covered by the sheet or film layer. The antimicrobial agent may be in powder form or in liquid form. In either form, the antimicrobial agent is capable of withstanding the bonding temperature without degradation or loss of its performance.

[0112] According to one embodiment, the polymer film or sheet layer covering the core can have antimicrobial properties. In one aspect, the polymer layer (e.g., a high impact polymer sheet) can cover the bottom surface, the entire thickness of the width, and a portion of the top surface of the core. In another aspect, the polymer film or sheet layer (e.g., a high impact polymer sheet with antimicrobial properties) can cover the top and bottom of the core and substantially all of the thickness of the width.

[0113] In one exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be added to the material used to make the sheet. The antimicrobial agent may be in powder form or in liquid form. In another exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be applied to the exposed surface or surfaces of the load-bearing structure, whether or not the surface is covered by a sheet or film layer. The antimicrobial agent may be in powder form or in liquid form. In either form, the antimicrobial agent is capable of withstanding the bonding temperature of the one or more sheets to the core without degrading or losing its performance.

[0114] In another embodiment, the porous surface (which may be the porous plate substrate described above), or the surface of the polymer core (e.g., a foamed polymer core or a polyurethane core) may be covered by a polymer sheet, with a portion of the top surface of the core exposed. The polymer sheet may be impregnated with an aqueous antimicrobial component, which may be in the form of an emulsion or dispersion, and at least one substantially non-leaching antimicrobial component that is substantially free of environmentally harmful materials. After impregnation with the antimicrobial component, the porous surface may or may not be further coated throughout or protected with a film layer.

[0115] In another embodiment, the porous surface, which may be a porous plate substrate, may be impregnated with an aqueous antimicrobial component having at least one polymer carrier that may be in the form of an emulsion or dispersion and at least one substantially non-leaching surface-active antimicrobial component that is substantially free of environmentally harmful materials.

[0116] In another embodiment, a non-porous plate substrate may be coated with an aqueous antimicrobial component having at least one polymer carrier that may be in the form of an emulsion or dispersion and at least one substantially non-leaching antimicrobial component that is substantially free of environmentally harmful materials.

[0117] For load bearing structures having a thermoplastic sheet on a core, the exposed surface may be porous, as described above. The porous material may be impregnated with an aqueous antimicrobial composition, which itself may form a film rendering the surface non-porous, as also described above.

[0118] In some embodiments, the surface of the porous material impregnated with the antimicrobial component may be non-porous after drying or standing, and may function as if it had been coated or covered with the above-described thermoplastic sheet or protective sheet.

[0119] The same emulsion or dispersion described above can also be applied to the exposed surface of a load-bearing structure having a core having two thermoplastic sheets running through it when the exposed surface is non-porous.

[0120] In any of the above disclosed embodiments, the antimicrobial agent may be added after the heat sealing process. In the embodiment where heat sealing is achieved after the antimicrobial agent is added, the antimicrobial agent used can maintain or not lose its antimicrobial properties during the bonding process.

[0121] In any of the embodiments having antimicrobial properties, edge bonding may be performed before or after coating with the antimicrobial layer.

[0122] Antimicrobial agents can help minimize the accumulation of bacteria on the load-bearing structure. However, edge seals and antimicrobial agents can help minimize the accumulation of dust, dirt or bacteria.

[0123] In other embodiments, the core may include a structural metal mesh to resist puncture of the surface.

[0124] In another embodiment, the above-mentioned supporting structure has antibacterial properties and / or puncture resistance properties, and may also have flame retardant properties and / or ultraviolet light protection properties.

[0125] In one embodiment of the invention, the load-bearing structure may be a pad platform having a top surface and a bottom surface separated from each other by a width having a thickness. The platform may be generally square or rectangular in shape. A box may be assembled from a plurality of load-bearing structures (e.g., pad platforms), each having a lightweight polymer core and a high-impact polymer sheet substantially covering the core, as described above. Pad platforms that may be used to assemble into a box may include interlocking members that mate together to form the box.

[0126] The edges of the load-bearing structure of the box may be joined by sealing tape, sealing chemical compositions, sealing fluids, or mechanical and / or heat sealing (eg, using ultrasonic heat sealing devices), as described above.

[0127] In one embodiment, when the above-described load-bearing structure can be assembled into a box having a bottom, a top and walls, the expansion can occur at one or more of the bottom, the top and the walls.

[0128] In some aspects, the lightweight, strong box assembled from the above-described plurality of movable load-bearing structures may also be puncture-resistant and / or flame-retardant and / or UV-protective, with or without antimicrobial properties.

[0129] One of the load-bearing structure or the dunnage platform of the box may also have a plurality of feet extending from the bottom surface of the structure, as described above.

[0130] In some embodiments, a structural metal mesh may be inserted into the core to resist punctures on the surface.The box may also have flame retardant properties and / or UV light protection properties.

[0131] The load-bearing structures of the present invention can be used to load, store or transport products that either cannot withstand such contamination or cross-contamination, are susceptible to damage, or have an undesirable perception of non-cleanliness. The present invention also relates to load-bearing structures that are used directly in clean rooms used to manufacture electronic parts, microelectronic devices, pharmaceuticals and drugs, food products such as snacks, or similar products that need to be kept clean from dust, dirt or bacteria. Goods can be loaded directly after manufacturing without the additional step of transferring the goods from the clean room to the load-bearing structure, thereby reducing steps, saving time, reducing the risk of human or mechanical, or contamination or damage. Edge sealing further increases the cleanliness of the load-bearing structure.

[0132] According to the present invention, a polymer core, for example, may be a closed cell foam core, such as an expanded polystyrene core, having an area adjacent to its surface to which a high impact polymer sheet (e.g., a polystyrene sheet) is bonded by heat and pressure. In one exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be added to the material used to make the sheet. The antimicrobial agent may be in powder form or in liquid form. In another exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be applied to at least one of the exposed surfaces of the sheet. The antimicrobial agent may be in powder form or in liquid form.

[0133] The load-bearing structure may also include a plurality of supports, which, as described above, can generally separate the bottom surface of the load-bearing structure from the ground and / or other support surfaces. The supports may also be spaced apart from one another, such as by manipulating the load-bearing device with a forklift and / or other moving machinery to fit into the space between the supports. In some embodiments, strips, bridges and / or other connectors may also be included, such as multiple supports (connecting multiple supports) that generally increase the strength and / or rigidity of the bottom. For example, the bridge may be made of wood, metal and / or various plastic materials (including polyolefins, polyesters, lead-free PVC, etc.), or any of the above-mentioned materials suitable for polymer sheets. In some embodiments, the strips or bridges are made of HIPS (high impact polystyrene) using an extrusion molding process. In addition, the bridges may be configured such that each of them spans two or more supports in a row, respectively, and may be fixed to the ends of the supports so that they are interconnected. For example, a suitable adhesive may be used to adhere the bridge. Furthermore, the bottom of the support member for fixing the bridge member may include a recess for positioning the bridge member so that the bridge member does not protrude from the bottom of the support member but is flush with the bottom of the support member.

[0134] The strips or bridges may extend between adjacent supports. Typically, the strips or bridges are spaced from the underside of the load-bearing structure, leaving space between the underside and the strips or bridges. In one embodiment, the bridges may be a plurality of wear-resistant components secured to the underside of at least some of the supports and adapted to bear a substrate on which the load-bearing structure may be disposed. Additionally, the strips or bridges may be configured such that each of them spans two or more supports in a row, respectively, and may be secured to each support wall to interconnect identically. For example, the strips or bridges may be secured to adjacent ends with a suitable adhesive.

[0135] The load-bearing structure may also include anti-skid components or further reinforced components, for example, the bottom surface of the load-bearing structure, or the bottom (if it is used as a component of the box), and / or the support may also include ridges, rib reinforcements, and / or other surface reinforcements, for example, to help improve the strength and / or rigidity of the bottom structure, especially the strength and / or rigidity under load. Some improvements also help to reduce any unexpected sliding of the box while it is in a stationary state. On the one hand, the improvement can make the bottom surface rough to reduce sliding. It is also believed that if each wall includes a plurality of ribs extending generally longitudinally, the ability of the support and / or bottom to resist compressive loads can be greatly improved.

[0136] Other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments as illustrated in the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0137] Figure 1 and1a are perspective views of the top side of the core of the load-bearing structure with and without extensions or supports, respectively;

[0138] Figure 2 and 2a They are shown respectively Figure 1 and 1a A perspective view of the bottom side of a core showing a plurality of grooves, valleys, indentations or channels;

[0139] Figure 3 A perspective view showing an embodiment of a component of the present invention;

[0140] Figures 3a to 3f A cross-sectional view showing an embodiment of a component of the present invention;

[0141] Figure 3g-3k Shows Figure 3f Different views of the components;

[0142] Figure 3l-3o Shows Figure 3e Different views of the components;

[0143] Figure 4 A load-bearing structure having a plurality of grooves, valleys, indentations or channels and a member cooperating with the grooves is shown;

[0144] Figure 4a - 4h shows different embodiments of the grooves, valleys, indentations or channels of the load-bearing structure;

[0145] Figure 5 A load bearing structure is shown having a plurality of members cooperating with a plurality of grooves, valleys, indentations or channels;

[0146] Figure 6 and 7 They are shown respectively Figure 1 and 1a A perspective view of the bottom side of a core showing a plurality of grooves, valleys, indentations or channels;

[0147] Figure 6a and 6c is a perspective view of the bottom side of the core showing a plurality of grooves, valleys, indentations or channels along the surface and extensions or supports in one direction;

[0148] Figure 6b is a perspective view of the bottom side of the core having a plurality of grooves, valleys, indentations or channels along the surface and on the side with a cavity extension or support of a capping member;

[0149] Figure 6d and 6eA cavity extension or support showing a carrier structure in which a cover member is arranged;

[0150] Figure 6f , 6g and 6i shows a perspective view of the underside of the core showing members extending substantially along the length / width of the core and having edge members;

[0151] Figure 6h illustrates views of edge members in various embodiments of a polymer core;

[0152] Figure 8 An embodiment of a box assembled using at least one load-bearing structure according to the present invention is shown and interconnecting components are illustrated;

[0153] Figures 8A-8E An embodiment of a box according to the present invention showing interconnected components during assembly is shown;

[0154] Fig. 9 An embodiment of a carrier structure according to the invention having recesses on the top side for fixing a phase change material is shown;

[0155] Fig.10 An L-shaped half shell of a box with a bottom made of a load-bearing structure is shown;

[0156] Fig.11 shows a line drawing of an L-shaped half shell of a box having a bottom surface made of a load-bearing structure having a phase change material phase located in a recess according to the present invention;

[0157] Fig.12 , 12a-12f, 12f-1, 12g show embodiments of a load-bearing structure with an extension or support according to the present invention, wherein the load-bearing structure has at least one polymer sheet bonded thereto and a sealing member for the edges of the polymer sheet;

[0158] Figures 12h-12m An embodiment of a load-bearing structure according to the present invention is shown, wherein the load-bearing structure has two polymer sheets bonded thereto and folded sealing members for the edges of the polymer sheets;

[0159] Fig.13 and 13a A method of sealing a polymer sheet to a polymer core using a sealing liquid in an embodiment of the present invention is shown;

[0160] Fig.14 , 14a and 14a-1 show an embodiment in which an adhesive tape is used as a sealing member;

[0161] Fig.14b and 14cAn embodiment of the present invention is shown in which the tape is applied to the edge of a polymer sheet bonded to a polymer core of a load-bearing structure;

[0162] Fig.14d Shows one side adhesive tape at the edge of a polymer sheet bonded to a polymer core of a load-bearing structure in an embodiment of the present invention;

[0163] Fig.14e shows the edge of a single polymer sheet bonded to a polymer core of a load-bearing structure in an embodiment of the present invention;

[0164] Fig.15 , 15a -15h shows an embodiment of a load-bearing structure without extensions or supports according to the invention, having a sealing member combining at least one polymer sheet and a polymer sheet edge;

[0165] Fig.16 and 16a An embodiment of a box with a tongue-and-groove seam in an embodiment of the present invention is shown;

[0166] Fig.17 and 17a Shows Fig.16 and 16a the bottom of the illustrated embodiment of the box;

[0167] Fig.18 , 18a and 18e show Fig.16 and 16a The wall panels of the embodiment of the box shown;

[0168] Fig.18b , 18c 18d and 18d respectively show a wall panel connected to a top panel, another wall panel, and a bottom panel in an embodiment of the present invention;

[0169] Fig.19 and 19a Shows Fig.16 a top plate of the illustrated embodiment of the box;

[0170] Fig. 20 Shows Fig.16 Assembly of the illustrated embodiment of the box;

[0171] Fig.21 and 21a -21e shows an embodiment of the invention with a base having different extensions or supports;

[0172] Fig. 22 , 22a and 22b show a wall panel fully formed or connected in a generally L-shaped structure for connecting with a top panel and a bottom panel in an embodiment of the present invention;

[0173] Fig.23 , 23a and 23b show a pair of wall panels fully formed or connected in a generally L-shaped configuration in another embodiment of the present invention, one of which is fully formed or connected to the top panel and the other is fully formed or connected to the bottom panel;

[0174] Fig.24 and 24b -24c shows a load-bearing structure with a depression in an embodiment of the present invention, wherein the depression is used to accommodate an edge protection body to accommodate a cargo support;

[0175] Fig.24a A load-bearing structure having a recess for receiving a component is shown;

[0176] Fig.24d A load-bearing structure having an extension or support and a recess is shown, wherein the recess is used to accommodate an edge protector without a guide groove;

[0177] Fig.24e A load-bearing structure is shown with a recess for receiving an edge protector, without guide slots or extensions or supports;

[0178] Fig.25 The load-bearing structure with edge protection and guide grooves is shown;

[0179] Fig.25a , 25b and 25c are partial cross-sectional schematic diagrams showing examples of load-bearing structures with edge protectors in embodiments of the present invention, wherein the edge protectors are located in depressions;

[0180] Fig.26 and 26a Examples of L-shaped and C-shaped edge protectors are shown respectively; and

[0181] Fig. 27 and 27a A load-bearing structure having an edge protector with guide members in an embodiment of the present invention is shown.

[0182] Fig.28 and 28a The height difference between the polymer core with and without extension members for support is shown.

[0183] Fig.29 and 29a The setup for load testing of polymer cores is shown. DETAILED DESCRIPTION

[0184] The detailed description that is made below is intended to describe the systems, devices and methods provided according to aspects of the present invention that will be exemplified below, rather than to represent the only way in which the present invention can be prepared or utilized. On the contrary, it is to be understood that the same or equivalent functions and components can be accomplished by different embodiments, wherein these different embodiments are also intended to be included in the spirit and scope of the present invention. In addition, unless limited, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention belongs. Although any method, device and material similar or equivalent to the method, device and material described herein can be used in the practice or testing of the present invention, only exemplary methods, devices and materials are described below. All publications described herein are incorporated herein by reference for description and disclosure, for example, designs and methodologies described in publications that can be used in conjunction with the present invention to be described. Only publications listed or discussed above, below and throughout the article with a publication date earlier than the filing date of the present application are provided. However, it is not acknowledged here that the inventor has no right to advance such disclosure by priority invention.

[0185] Strong and lightweight load-bearing structures can be used to transport cargo by air, land, and sea. Although all modes of transporting cargo can feel the benefits of lightweight load-bearing structures, the economic benefits of lightweight load-bearing structures are greater for air transport than for other modes of transportation.

[0186] The present invention relates to a strong, lightweight load-bearing structure comprising a lightweight polymer core covered by one or more polymer sheets or films or combined with the sheets or films. The lightweight polymer core can be made of a closed-cell foam core comprising polystyrene foam, polyurethane foam, vinyl foam, acrylic foam or phenol foam, as described above. As described above, the density of the foam can be in the range of about 15 kg per cubic meter to about 45 kg per cubic meter, for example in the range of 20 kg per cubic meter to about 35 kg per cubic meter, even for example in the range of about 21 kg per cubic meter to about 30 kg per cubic meter, and also for example in the range of about 23 kg per cubic meter to about 25 kg per cubic meter. As described above, the density of the foam is insignificant and has substantially no effect on the overall strength of the load-bearing structure, although it can affect strength to some extent. For higher density foams, the polymer core can have a smaller thickness. However, as described above, due to the limited space in the air shipment of cargo and the need to have a lighter weight load-bearing structure to save on transportation costs, a higher density foam that would result in a heavier overall weight may be undesirable. Therefore, for air shipment of cargo, the thinner the core, the lighter the weight of the core, the more suitable it is for use in a load-bearing structure. For example, a more ideal thickness of a core suitable for air shipment of cargo may vary from about 120 mm to about 130 mm. At these thicknesses, the load-bearing structure described above can withstand deformation testing without using a substantially higher density core.

[0187] In order to improve the load-bearing capacity (such as the ability to transport more weight) without making the load-bearing structure heavier, the core can include at least one groove, valley, indentation or channel on the bottom side and a corresponding member that cooperates with the at least one groove, valley, indentation or channel. This groove, valley, indentation or channel can be of any shape, for example, a substantially half-moon or square side. The corresponding member can also be of any shape and can include a central portion having a cross-section of any shape, for example, a substantially dome-shaped cross-section, a substantially trapezoidal cross-section, a substantially triangular cross-section, a substantially rectangular cross-section, etc., and the central portion may or may not have wing-shaped members extending from both sides of the lower portion of the central portion. The central portion can be filled into one of the at least one groove, valley, indentation or channel. If present, the wing-shaped member can have a small thickness so that when combined with the load-bearing structure, the member is substantially flush with the remainder of the bottom side of the load-bearing structure to present a smoother feel with very small visible protrusions or ridges. A load-bearing structure having at least one groove, valley, indentation or channel on the bottom side of a polymer core and the at least one groove, valley, indentation or channel being bonded to or covered by at least one member has improved properties, such as the ability to transport heavier objects compared to a load-bearing structure without the groove, valley, indentation or channel.

[0188] Figure 1 In the embodiment, the foamed polymer core 10a (eg, a polystyrene core) is a conventional core having a width 12 ( Figure 1 ) in the shape of a rectangular slab having a thickness 14a which can be of any size, for example, about 1 cm to about 5 cm. The core 10a can have a smooth top side 16a which can be partially or completely covered with a polymer layer, for example, a high impact polymer sheet 67 such as a high impact polystyrene board, which can have a length of approximately about 4 feet and a width of 40 inches. The polymer sheet 67 can have a thickness of about 1 mm to about 5 mm. The smooth top side 16a can generally transition to a width 12 at its circumference having an edge 12a. As shown in FIG. Figure 2 As shown in FIG. 1 , the bottom side 18 of the core 10a may include one or more extensions or supports 20 - 28 , but some embodiments may not include multiple extensions or supports, such as Figure 1a and 2a If present, these extensions or supports may extend from the bottom side 18a by a length of, for example, about 2 to 6 inches (about 5 cm to about 20 cm).

[0189] Figure 1a and 2a is with Figure 1 and 2 A similar embodiment, but without the multiple extensions or supports. Figure 2a , Figure 2a The bottom side of the load-bearing structure is shown with the edge 12 a adjacent to the spaces 42 , 44 , 46 , 48 on the bottom side 18 .

[0190] The load-bearing structure 10 also has a width 12 with a thickness 14, which is the combined thickness of the core 10a and the panels 67. Cargo may be loaded on the top side 16a of the load-bearing structure 10. The cargo may be fragile or non-perishable and may include fresh vegetables and fruits, poultry and meat products, drugs and pharmaceuticals, electronic components and equipment, etc.

[0191] In some exemplary embodiments, the polymer core may include at least one groove, valley, channel, indentation, and / or other recessed portion, such as Figure 2 , 2a, 6, 7 are typically located on the bottom surface of the polymer core and / or if a support member is present, they are typically located on the side of the support member. These grooves, valleys, channels, indentations and / or other recesses help to reduce the weight of the polymer core, and at least one groove, valley, channel, indentation and / or other recess can be cooperated with a component or assembly to further enhance the strength and / or rigidity of the load-bearing structure obtained as described above.

[0192] Figure 3 and 3a Examples of components or assemblies 17 are shown in perspective and cross-sectional views, respectively. Typically, the component or assembly can be attached to the load-bearing structure and can be, for example, bonded or welded to the polymer core and / or, if the component or assembly 17 is attached before covering or bonding the polymer core with a polymer layer, sheet or film (e.g., a high-impact polystyrene layer, film or sheet), the component or assembly can be assembled into a corresponding component of the polymer core, such as Figure 2 , 2a , 6, 7 in the grooves 13, 13', 15, 15', 15" of the polymer core 10a. In some embodiments, the grooves may also extend to the side surfaces of the support members 20-28, for example Figure 2 , 5 , 6 and Figure 6a , 6b and 6c of the groove 13, 13 ', 13 "side 13a, and can also extend to the end of the support member, such as Figure 6a and 6c The extension of the groove on the support member may be desirable, for example, to further enhance the strength and / or rigidity of the resulting load-bearing structure, particularly at supports that may be subject to increased pressure when, for example, stacking the load-bearing structure, and / or to enhance durability against damage to the support member. In some embodiments, any of the supports 20-28 may be hollow, and the extension of the groove on the hollow support member may increase the rigidity or strength of the support member.

[0193] In some embodiments, the grooves may extend in only one direction on the polymer core, e.g. Figure 2 and 6c extends in a first direction, and Figure 6a and 6cThe grooves may extend in a second direction in a polymer core. This may be desirable, for example, to further enhance the strength and / or rigidity of the resulting load-bearing structure in a particular direction, such as in a direction in which the resulting load-bearing structure may be subjected to increased or enhanced loads or pressures. The grooves may also extend in both the first and second directions on a polymer core, such as Figure 6 , 7 , 21b, 21c, 21d and 24a.

[0194] As another example, if the polymer core is covered or bonded with a polymer film, layer or sheet, the member or component 17 can be, for example, bonded, bonded or fused to the polymer sheet, layer or film. The member or component 17 generally conforms to the surface of the polymer core if the member or component is present before covering with the sheet, film or layer, or generally conforms to the surface of the load-bearing structure if the member or component is present after covering or bonding the core with the polymer film, sheet or layer.

[0195] In one embodiment, the member or assembly may further include a wing member, such as Figure 3a -3d, 17a shown in 4a-4f, is used to enhance rigidity / strength and / or facilitate assembly of the member or component 17 to the polymer core. It may be generally desirable that the member or component 17a conforms to the surface of the polymer core because this can result in a substantially uninterrupted and / or smooth surface without undesirable protrusions that may interfere with or damage other parts or load-bearing structures. The member or component 17 may include a raised central portion as shown and a flat conforming portion, such as Figure 3 and 3a -3d shows a flat portion 17a and an elevated central portion 17b. The flat portion 17a may generally be arranged substantially flat and / or flush with the surface of the polymer core 10a, while the elevated central portion 17b may protrude into the polymer core 10a, such as, for example, into a groove, valley, channel, indentation and / or other recess 13, 13', 15, 15', 15", as shown in FIG. Figure 4 , 4a -4f with a member or assembly 17 inserted into the recess 13 of the polymer core 10a, or as shown in Figure 5 The plurality of members or assemblies 17 shown in FIG. 1 are inserted into the groove 13' between the extensions 21, 24. The flat portion 17a may extend beyond the dimensions of the raised central portion 17b, such as Figure 3 and 3a -3d is shown as a wing-shaped member, the flat portion 17a can also have the same size or substantially the same size as the raised central portion 17b, such as Figure 3b , 3eThe raised central portion 17b may have any suitable cross-sectional shape, such as, for example, a semicircular, rectangular, triangular and / or any other suitable form, such as Figure 3a and 3b The semicircle 17b in the Figure 3c Triangle 17b in Figure 3f Polygon 17b in and Figure 3d and 3e The raised center portion may have straight sidewalls or tapered sidewalls. It is generally desirable to select a cross-sectional shape that conforms to or compressibly / frictionally fits into a corresponding groove of the polymer core 10a. The corresponding groove may have the same or substantially the same shape as the raised center portion 17b, such as Figure 4c , 4d , 4e, 4g and 4h, the groove 13 may also be of different shapes, such as Figure 4a and 4b The depression may have straight side walls or tapered side walls. The corresponding groove may also be modified to conform to the raised center portion 17b and accommodate the flat portion 17a having a wing-like member, such as Figure 4f As shown in the groove 13 in the embodiment, the groove includes an indentation to fit the wing-shaped member of the flat portion 17a into the indentation. The member or component 17 may also include, for example, a cavity portion 17c, which may, for example, help reduce the weight of the member or component 17 and / or enable the member or component 17 to deform or compress when inserted into the groove 13, 13', 15, 15', 15". The hollow portion 17c may also be formed by a partition such as Figure 3e and 3f The spacers 17d in the hollow portion 17c may be divided into multiple spaces, which may also, for example, increase structural support, rigidity or strengthen the hollow portion 17c. Such deformation or compression may be desirable so that the component or assembly 17 can be compressively or frictionally fitted into the groove. If desired, the component or assembly 17 can generally be fitted into the groove before the polymer sheet is applied, as described below, so that the component or assembly 17 can be held together with the polymer core 10a by the polymer sheet, which may also make the component or assembly 17 flat and / or make the presence of the component or assembly 17 less obvious.

[0196] The wing-shaped member 17a can be of uniform thickness or can be tapered toward the end so that the member or component 17 further conforms to the surface of the core when it appears before the core is covered with a sheet or film or before the sheet is combined with the core, or conforms to the surface of the load-bearing structure when the member or component 17 appears after the core is covered with a sheet or film or combined with the core.

[0197] The member or component 17 may also be in the form of a polygon, for example Figure 3e and 3f As shown in the components, Figure 3g , 3h , 3i, 3j and 3k show Figure 3e perspective view, front view, rear view, top view, bottom view and side view of the components in the Figure 3l , 3m , 3n and 3o show Figure 3f Perspective view, front view, rear view, top view, bottom view and side view of the components.

[0198] In some embodiments, the support member may include at least one enlarged groove, valley, channel, indentation, and / or other recess that may cooperate or engage with a member or component to further enhance the strength and / or rigidity of the resulting load-bearing structure, as described above. In some embodiments, the enlargement may include a cavity space within the support member body, such as Figure 6d and 6e The enlarged cavity space in the support member can, for example, significantly reduce the overall weight of the polymer core by omitting or removing a relatively large amount of material in the support member.

[0199] In some embodiments, the cavity support may include additional components that are used to increase the strength and / or rigidity of the resulting load-bearing structure by reinforcing and / or closing the cavity space, such as Figure 6b , 6d and the capping member 13c in 6e. The capping member 13c can be substantially similar to the member or component 17, but is typically larger and / or its shape is more like the overall shape of the support member 20, such as a more square rectangle, so that the capping member 13c can completely and effectively close the cavity space 20a. For example, the capping member 13c can typically be at least the same width as the width 20b of the cavity space 20a or a width greater than the width 20b of the cavity space 20a. The capping member 13c and / or the cavity space 20a may also include additional components for sealing the capping member 13c, such as, for example, corresponding steps, grooves, ribs, indentations / elevations and / or any other appropriate components. For example, Figure 6d and 6e The corresponding steps 13c' and 20c of the cavity space 20a and the cover member 13c are shown respectively, so that the cover member 13c can be sealed on the cavity space 20a and provide a flat end to the support member 20, as shown from Figure 6d The unclosed arrangement to Figure 6eAs with the use of member or assembly 17, if desired, the capping member 13c can be generally assembled into the cavity space 20a before the polymer sheet is applied, as described below, so that the capping member 13c is held together with the polymer core 10a by the polymer sheet, which can also make the capping member 13c flat and / or make the presence of the capping member 13c inconspicuous, so that it overlaps with the rest of the polymer core 10a, for example.

[0200] In other embodiments, the cavity space 13 may be tapered. When the cavity space 13 is tapered, the components are also tapered accordingly to better fit the recess. In one aspect, the taper may be, for example, Figure 4d Similarly toward the top of the supports 20-28. In another aspect, Figure 4d Instead, the taper may be toward the bottom of the supports 20-28. A taper toward the top of the supports may make it easier to fit with the components, and these components may substantially fill the hollow space of the extension. Although the taper may be toward the bottom, the extension may not fully fill the hollow space inside, and the components may not substantially correspond to the shape of the recesses in order to facilitate the insertion of these components into the recesses. As described above, these components may include a hollow center portion to minimize the weight of the overall structure. At the same time, at least one depression such as a groove, valley or channel on the bottom side of the core extending below the side of each extension, through its bottom, and above its side through the entire length or width of the load-bearing structure, and at least one corresponding component that cooperates with one of the at least one groove, valley, indentation or channel can further enhance the extension and its connection to the bottom surface of the polymer core.

[0201] In some embodiments, the bottom of the polymer core may include at least one depression, such as a groove, a valley, an indentation, or a channel, which may extend along the entire length and / or width of the bottom of the polymer core, such as Figure 6f , 6g 6i, the polymer core 10 includes a recess 15-1 extending substantially along the entire length of the bottom side 18 as shown. In one example, the recess 15-1 can span, for example, at least about 75%, another example, at least about 80%, or even, for example, at least about 85% of the length or width of the polymer core 10. The load-bearing capacity of these structures is maintained even when the overall weight and / or vertical height of the polymer core 10 is significantly lower than when there is no such recess 15-1 that cooperates with the corresponding member (having a greater weight and / or greater thickness). For example, as Fig.28 and 28a As shown, the polymer core 10 can produce an overall vertical height of 120 mm ( Fig.28 ), the vertical height of the polymer core 10 without such a depression is 139 mm ( Fig.29 Dimension E in FIG. 4 ), when loaded with the same cargo load 490, a uniform cargo item height C is used as shown to Fig.28a The polymer core 10 of the shown depression 15-1 produces an overall lower vertical height A, while for the same cargo height, there is no Fig.28a The polymer core 10 with the depressions 15-1 shown has a higher height. It was found that with, for example, a pair of long depressions 15-1 on the bottom side of the polymer core 10 (e.g., 120 mm or 130 mm thick), the deformation from a constant load after hours or days was within an acceptable range, similar to or better than a thicker polymer core 10 (e.g., 139 mm) without the depressions 15-1, as described in the following examples.

[0202] As described, the recess 15-1 can be substantially separate and / or unconnected from other components, such as the recesses 13, 13', so that the recess can remain intact along its entire length to provide better strength and / or rigidity (compared to if the recess was interrupted). The recess can also accommodate an insert or other component that can cooperate with the recess 15-1, and the insert or other component itself can also be full-length, providing better strength and / or rigidity (compared to if they are multi-piece or interrupted). The longer recesses 15-1 can be spaced apart from each other and substantially parallel to each other, extending substantially along the width or width of the bottom side of the polymer core 10.

[0203] As described above, the depressions 15-1, 13 or 13' can exist as at least one single depression or at least one group of depressions. The group of depressions, such as 15-1, is closely spaced parallel depressions, such as grooves, valleys, indentations or channels. A group of depressions can be similar in appearance to a single depression as shown in 15-1, but if observed more closely or if magnified, one can distinguish at least two or more closely spaced depressions. The depressions within a group can have the same or different lengths, shapes or depths. The internal spacing between a group of depressions can be smaller than the spacing between adjacent groups. Each group of depressions (if present) can also be interposed with a single depression.

[0204] At least one of the recesses can cooperate with a corresponding member 17. In one embodiment, all recesses cooperate with a corresponding member 17. In another embodiment, not all groups of recesses (if more than one group exists) cooperate with a corresponding member 17. In another embodiment, not all recesses within a group can cooperate with a corresponding member 17.

[0205] As described above, depressions such as 15-1 can have different lengths and can be present at different locations on the load-bearing structure. In fact, there can be a variety of different combinations of depressions in a single load-bearing structure, for example, a single depression or a combination of groups of depressions of different lengths, widths, depths, shapes and quantities. Without being bound by any particular theory, depressions such as depression 15-1 may not necessarily extend along the entire length or width of the polymer core 10 to achieve the desired rigidity enhancement and / or increase, for example, the load on the polymer core 10 can generally be mostly present in the center or inward from the edge 12, so that the increased strength or rigidity can generally be more ideal toward the inside, rather than at the edge 12. The reduced length can also generally retain a residual area near the edge 12, which may be less prone to flexing or bending (compared to the depression extending along the entire length), because the depression of the entire length will promote flexing along the span perpendicular to the depression.

[0206] As described above, the corresponding member for each recess (whether or not the recess is part of a group of recesses) may include at least one raised portion 17 for each recess, and may or may not include any flat portion 17b, such as a wing-like portion. In some embodiments, a member for a group of recesses (if all recesses in a group of recesses cooperate with the member 17) may include at least two raised portions 17a, which may have a cross-section of any shape, such as a wing-like member, with or without a flat portion 17b extending from the lower portion of both sides of the central portion 17a, or a combination of cross-sections of any shape, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, or a substantially triangular cross-section, etc. The raised portion 17a (if there is more than one group) may have a cross-section of any shape, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, or a substantially triangular cross-section, etc., with or without a flat portion 17b extending from the lower portion of both sides of a central portion 17a, such as a wing-like member, or a combination of cross-sections of any shape, such as a substantially dome-shaped cross-section, a substantially rectangular cross-section, or a substantially triangular cross-section, etc. When matched, the central portion 17a can substantially fill one of at least one depression 15-1 of corresponding shape, such as a groove, a valley, an indentation or a channel. The central portion and the wing-shaped member, if present, can be directly or indirectly adhered to or bonded to the underside of the polymer core. For a given load-bearing structure with such a depression and with or without a corresponding member, the core can be combined with one or two polymer films or sheets. In one embodiment, the member can cover the polymer core or be combined with the polymer core before the polymer core is covered by one or more polymer sheets or films or is combined with one or more polymer sheets or films. In another embodiment, the member can cover the load-bearing structure or be combined with the load-bearing structure after the polymer core is covered by one or more polymer sheets or films or is combined with one or more polymer sheets or films.

[0207] As described above, in one aspect of any of the above and illustrated embodiments, one or more rows of at least one depression (e.g., grooves, valleys, indentations, or channels) on the bottom side of the core may exist along one direction on the bottom side of the core and on at least one corresponding component that cooperates with the at least one groove, valley, indentation, or channel. In another aspect of any of the above embodiments, although it is not specifically shown under what circumstances at least one depression exists on the bottom surface of the support members 20-28, similar to 24a, in the absence of the depression 12b for accommodating the edge protector 11, one or more rows of at least one depression (e.g., grooves, valleys, indentations, or channels) may exist along multiple directions on the bottom surface of the core and on at least one corresponding component that cooperates with one of the at least one groove, valley, indentation, or channel.

[0208] like Fig.24a As shown, there are 3 groups of recesses 13 in a first direction and 2 groups of recesses 13 in a second direction perpendicular to the first direction. In other embodiments, there may be fewer or more groups of recesses 13 if desired. In the illustrated embodiment, the recesses 13 extend to the sides of the supports 20-28. In other embodiments, the recesses 13 may also extend to the bottom side of the supports 20-28. In some embodiments, the recesses 13 may not extend toward the supports 20-28. These recesses 13 may cooperate with corresponding members 17, as described above.

[0209] In one example, at least one recess 15 or 15' substantially spans at least about 75%, at least about 80%, or even at least about 85% of the length or width of the load-bearing structure. A recess may include a single recess or a group of closely spaced parallel recesses (all recesses have the same length, but may have the same or different widths or depths).

[0210] The load-bearing structure generally supports loads many times its own weight. For example, about 10 times to about 20 times, for example about 15 times to about 18 times. If the load-bearing structure does not have the required load-bearing capacity, deformation or bending of the structure may occur after about one day or more, for example after about three days or more, or even more such as after about seven days or more. These bendings may occur around the center or toward the periphery of the structure. These capacities can be tested and / or measured using established standard test procedures such as ASTM test procedures. One test procedure may be ASTM1185-2009 Section 8.4 (bending test), and the structure must pass this test. Passing the test is also important for safety factors. Structures that deform more than the standard will deform too much, which may cause safety problems.

[0211] During the static test, the load-bearing structure is subjected to a bending test. As described above, the thicker the core, the greater the chance that such a structure will pass the test. However, when limited space requirements are compared with the need to produce a good product (without sacrificing either), the structure of the present invention uses a longer depression that cooperates with the corresponding member, compared to using a plurality of (e.g., at least three, and for example at least five) substantially shorter depressions that cooperate with the corresponding member, and can maintain the same advantages, or even more advantages. In some such embodiments, as described above, the thickness of the core can be about 120 mm to about 130 mm without increasing the density of the core.

[0212] As described above, the load-bearing structure of the present invention is particularly suitable for air shipment of cargo with limited space. The improved load-bearing characteristics of the load-bearing structure of the present invention with the potential to reduce the overall thickness and / or weight of the load-bearing structure can actually allow carriers to ship additional or more rows of products per load-bearing structure in some cases, such as air shipment of smartphones, sheet-like items, or other similar thin products, without increasing weight, or with as little weight increase as possible, thereby further saving costs.

[0213] In some embodiments, additional components may be present intermittently or continuously around some of the edges. The components may generally improve or increase the strength of the edges of the load-bearing component, thereby minimizing wear or damage during use or repeated use. Generally speaking, additional components are such as edge protectors. Edge protectors are effective in protecting and improving the strength of the edges to prevent wear. However, as described above, such components may also increase the weight of the load-bearing structure when used.

[0214] The invention also relates to a component that can improve the strength of the edge without increasing the weight of the load-bearing structure. In fact, such a component can reduce the weight of the load-bearing structure. The core can include a portion of a roughened edge or a notched edge, such as a serrated edge. Figure 6f An example of a polymer core 10 having such a component is shown in a perspective view in FIG. Figure 6h , a view of a portion of any of the various embodiments of the polymer core 10 described therein is shown. Figure 6hA polymer core 10 is shown having a feature 12f that may be present along the span of edge 12. As shown, feature 12f may be serrated and / or a series of small indentations that generally disrupt the continuity of edge 12f having the feature. A roughened edge such as feature 12f may be integral to the polymer core 10. The roughened edge portion may be present on the core 10 and the shape may be maintained after being combined with one or more polymer sheets. Typically, the roughened edge portion may be formed on the core during the process of forming the core or may be introduced after the core is manufactured. The roughened edge may also be achieved subsequently by processing, such as by cutting recesses and / or compressing edge 12 to form the roughened edge. In one embodiment, the roughened edge portion may be present on at least the bottom edge 18 of the width portion connecting the top side and the bottom side. In another embodiment, the roughened edge portion may be present anywhere along the width portion of the core 10. As described above, the roughened edge portion may be present continuously or discontinuously along the width portion connecting the top side and the bottom side, such as Figure 6f . Although the core with the roughened edge portion uses less material when there are some indentation areas on the edge of the core due to the roughened edge, the edge of the resulting core is stronger than the core with uniform edges all around. Without being bound by any particular theory, the roughening and / or interruption of the continuity of the edge 12 can have less material for potential damaging objects to get stuck and / or there is a smaller amount of material that may break at one time, rather than removing a large piece of material due to the continuous edge. The roughened edge portion can include teeth of any length and shape. For example, the ends of the teeth can be substantially smooth or can be slightly pointed. Each tooth can have a length that is approximately equal to the thickness of the width portion of the edge, or in another example, a length that is approximately half the thickness of the width portion of the edge, or in yet another example, the length of each tooth can be any length between half the length and the above-mentioned full length. As described above, the roughened edge portion does not extend further from the side of the core than the unroughened edge portion. Therefore, the roughened edge does not increase the size of the unroughened load-bearing structure.

[0215] Typically, the form or shape of the core determines the final form or shape of the load-bearing structure.The notched edges of the core are retained after bonding with the polymer sheet or film.

[0216] If edge protection is the primary purpose, new edge protector features such as a roughened edge may be present in any of the embodiments described therein as well as in any embodiment without any of the recesses described above.

[0217] In one exemplary embodiment, a load-bearing structure for loading, transporting or storing goods is provided, the load-bearing structure having: a foamed polymer core, the foamed polymer core having a top side, a bottom side and a width portion, the width portion having a thickness connecting the top side and the bottom side; at least one polymer sheet, the polymer sheet having a first side with an outer edge portion and a second side, the second side and its outer edge portion being bonded to the foamed polymer core on at least a portion of the top side and the width portion of the foamed polymer core. The load-bearing structure accordingly has at least one member for reducing the overall weight of the load-bearing structure and increasing the strength of at least one of the edges of the load-bearing member, the member including a portion of a roughened edge. The load-bearing structure may or may not include a support member extending from the bottom side of the polymer core. The load-bearing structure may or may not include any depressions or groups of depressions, as described above.

[0218] In some embodiments, in order to have better compatibility when covering, combining or bonding, these corresponding components or components can generally be made of the same or similar materials as the polymer core or polymer sheet, as described below, such as polystyrene or high impact polystyrene (HIPS). It can also be required to use the same or similar materials so that the entire load-bearing structure can be arranged or circulated as a unit, for example, without material separation. Generally, the components or components can be formed by materials that are stronger and / or more rigid than the entire polymer core, thereby providing more significant reinforcement by adding minimal materials. For example, such as in the case of adding 8 components or components 17 in grooves 13, 13', multiple components or components can increase the total increased strength by at least 10% to 15% and / or the additional peel strength (racking strength) of up to 25%. The components or components can be manufactured, for example, by extrusion, die casting and / or other appropriate technologies. The components or components can be formed, for example, in a certain length and cut to any size, or cut to the size suitable for the appropriate groove.

[0219] In addition to the same or similar materials as the polymer sheets, suitable materials for the components or assemblies, whether present on the load-bearing structure before or after the core is combined or bonded to one or more sheets, can include any metal and polymer material, as long as such material can produce a rigid or significantly rigid part. Examples of suitable materials can include, but are not limited to, polymers that can be molded, thermoformed, or cast, for example. Suitable polymers include polyethylene; polypropylene; polybutylene; polystyrene; polyester; polytetrafluoroethylene (PTFE); acrylic polymers; polyvinyl chloride; acetal polymers such as polyoxymethylene or polyoxymethylene resins (available from DuPont); natural or synthetic rubbers; polyamides or other high temperature polymers, other high temperature polymers such as: polyetherimides like ULTEM®, polymer alloys such as Xenoy® resins which are composites of polycarbonate and polybutylene terephthalate, Lexan® plastics which are copolymers of polycarbonate and isophthalate terephthalate resorcinol resins (all available from GE Plastics); polyarylates or aromatic polyester amides such as aromatic polyesters containing as one component at least one compound selected from the group consisting of: Liquid crystal polymers of amide: aromatic hydroxyhydroxy acids (such as hydroxybenzoates (rigid monomers), hydroxynaphthoates (elastic monomers)), aromatic hydroxyamines and aromatic diamines (exemplified by U.S. Pat. Nos. 6,242,063, 6,274,242, 6,643,552 and 6,797,198, the contents of which are incorporated herein by reference); polyester imine anhydrides with terminal anhydride groups or lateral anhydrides (exemplified by U.S. Pat. No. 6,730,377, the contents of which are incorporated herein by reference), or combinations thereof. Some of these materials are recyclable or are made to be recyclable. Fermentable or biodegradable materials can also be used, and the fermentable or biodegradable material can include any biodegradable or biofermentable polyester, such as polylactic acid resin (including L-lactic acid and D-lactic acid) and polyacetic acid alcohol (PGA), polyhydroxyvaleric acid / hydroxybutyric acid resin (polyhydroxybutyrate (PHBV)) (copolymer of 3-hydroxybutyric acid and 3-hydroxyvaleric acid (3-hydroxy pentanoic acid (3-hydroxy valeric acid)) and polyhydroxyalkanoate (PHA) copolymers and polyester / polyurethane.Some non-fermentable or non-biodegradable materials can also be processed to be fermentable or biodegradable by adding specific additives, for example, any aerobic-biodegradable additives such as D2W™ provided by Symphony Environmental, Borehamwood, United Kingdom, and TDPA® manufactured by EPI Environmental Products Inc. Vancouver, British Columbia, Canada.

[0220] In addition, any polymer composite material may be used, such as an engineered prepreg or composite material, where the polymer is filled with pigments, carbon particles, silica, glass fibers, or mixtures thereof. For example, a mixture of polycarbonate and ABS (acrylonitrile-butadiene-styrene) may be used. For another example, carbon fiber and / or glass fiber reinforced plastics may also be used.

[0221] Suitable metals or metal materials may include metals and metal alloys, such as aluminum, steel, stainless steel, nickel-titanium alloys, and the like.

[0222] Moisture, dust and / or residual product and bacteria that grow on them can lead to product contamination or at least cross contamination and can also render unusable or dangerous to reuse without the previous strong decontamination effect if the load-bearing structure is reused for goods that are different from the previous goods (e.g. different food types such as poultry, fresh vegetables and fresh fruits, or even the same product type). Even if the load-bearing structure is remade, dust and / or moisture and bacteria that grow on them can lead to contamination of the goods loaded on the structure. Dust and / or moisture and bacteria can easily hide, grow or accumulate in the seams between layers of material if there are defective connections and / or bonds between the layers.

[0223] Typically, when the polymer film is normally bonded to the polymer core, heat and pressure are applied so that the portion of the polymer core near the bottom side 18 surface forms a substantially reinforced composite with the portion of the polymer sheet 67 near the bottom side surface of the polymer sheet 67. In addition, a portion of the polymer core near the edge 12 and in close relationship with the bottom side 18 is bonded to a portion of the polymer sheet 67.

[0224] However, even if the bond between the bulk of the polymer core and the polymer sheet is strong enough to produce a reinforced load-bearing structure with and without defects, there is still a need to improve the bond between the periphery of the polymer sheet and the polymer core in order to minimize or eliminate any defects in which dust, dirt and / or moisture often hides, grows or accumulates, and when there are connection and / or bonding defects between layers, they often hide, grow or accumulate in the seams between layers of material.

[0225] like Figure 1 , 1a , 2 or 2a, the load-bearing structure or platform 10 may include a lightweight polymer core 10a covered by a polymer sheet or two polymer sheets 67 as described above, and a polymer sheet 67 or 68 (such as Fig.12 and 15 The seams between the surfaces of the polymer sheet (as shown) and the core, or the seams of the edges formed by overlapping and / or abutting one polymer sheet with another polymer sheet, can be sealed using a sealing member, for example, a sealing liquid, a heat-activated adhesive, a sealing compound, or a mechanical and / or heat seal, and may include an ultrasonic sealing device, thereby minimizing or eliminating areas where moisture, dust and / or residual product and bacteria that grow on dust or moisture may hide, grow and / or accumulate.

[0226] A sealing member is applied near the outer edge of one or more polymer sheets, for example, at the periphery of the outer edge of polymer sheet 67 or polymer sheets 67, 68. Although a larger portion can be sealed, it is sufficient to seal a smaller portion of the outer edge with the sealing member. The sealing member is used to seal, for example, about 4 mm to about 12 mm from the periphery, more preferably about 5 mm to about 10 mm from the periphery, and more preferably about 5 mm to about 8 mm from the periphery of the polymer sheet. As described above, during the process of manufacturing the load-bearing structure, the remaining bonding area of ​​the polymer sheet including the outer edge is bonded using heat and / or pressure. Fig.13 and 13aIn the embodiment of the present invention, for example, a sealing member is present at about 7 mm from the outer edge of the second sheet 68. Examples of heat-activated adhesives may include, but are not limited to, adhesives containing ethylene alpha olefin copolymers, such as adhesives disclosed in U.S. Patents 6,319,979, 6,107,430 and 7,199,180; metallocene complex-based adhesives, wherein the adhesives include adhesives containing substantially linear ethylene / 1-octene copolymers, which can be purchased from Dow Chemical Company, and also include adhesives disclosed in U.S. Patents 8,222,336 and 8,163,833; metallocene complex hot melt adhesives including adhesives disclosed in U.S. Patent 8,476,359; propylene based hot melt adhesives, including adhesives containing non-metallocene complexes, metal-centered, heteroaryl ligand-catalyzed propylene and ethylene copolymer adhesives; active hot melt adhesives such as disclosed in U.S. Patent 8,507,604; including U.S. Patent 8,475,046 and 8,240,915; adhesives containing metallocene complexes and non-metallocene polymers, such as the adhesives disclosed in U.S. Pat. No. 8,475,621; adhesives containing ethylene alpha-olefins, such as the adhesives disclosed in U.S. Pat. No. 6,107,430; hot melt adhesives containing bulk polymers, such as the adhesives disclosed in U.S. Pat. No. 8,501,869; polyolefin adhesives such as those disclosed in U.S. Pat. Nos. 8,283,400 and 8,242,198, all of which are hereby incorporated by reference in their entirety.

[0227] The sealing liquid can be any solvent that slightly dissolves the core and / or polymer sheet during the sealing process, provided the liquid is non-toxic. It is also desirable that the liquid has a moderately high solubility coefficient for the core and / or polymer sheet so that a small amount of liquid is sufficient. The liquid may be slightly volatile or relatively non-volatile at room temperature. Examples may include chloride solvents such as tetrachloroethylene; or some cyanoacrylate adhesive compounds. As previously described, the liquid can be applied to the edges of the polymer sheet and the core or the seam between two polymer sheets by a dispensing device. Fig.13 An example is shown. The application may be done after the bonding process, particularly if the liquid is relatively volatile at room temperature and dries relatively quickly.

[0228] The sealing compound may comprise any relatively non-volatile liquid and may be in liquid form, processed form such as a semi-liquid composition comprising a liquid and solid particulate mixture or suspension, solid form such as encapsulation of any liquid adhesive or sealing composition.

[0229] Processed sealing chemistry such as suspensions may have lower volatility than pure solvents or even compounds, so that it can be applied in addition to being dispensed from a dispensing device such as a box, wherein the box, although similar to a plastic squeeze bottle or syringe as described above, has a larger opening at its dispensing end, which is located on any edge of the polymer sheet before or after the bonding process between the core and the board, depending on the activation temperature of the composition. In some embodiments, the suspension composition may include a mixture of sealing liquids that are the same or similar to the powdered polymer material used in the manufacture of the polymer sheet as described above. For example, when the polymer sheet is made of high impact polystyrene (HIPS), the powder may include powdered polystyrene. The sealing liquid may be relatively non-volatile, so that the liquid will not evaporate substantially before the board with the core and / or the bonding process between the boards. In one example, a solvent mixed with a solid, such as a tetrachloroethylene solvent mixed with HIPS powder, may be included to form a suspension that can be applied as described above. Such a suspension can be dried after application, and, for example, if heat activation occurs at a later stage, the particles can help to seal.

[0230] When the treated chemical sealing composition is in solid form which may include small encapsulated particles, which encapsulate any liquid of the sealing composition, which may be a solvent, suspension, or other liquid, pressure or heat and pressure may be applied for activation to crush or melt the capsules and release the adhesive.

[0231] Fig.12 , 12a -f displays the information such as described and Figure 1 and 2 A portion of an example of a load-bearing structure 10 with extensions or supports is shown, Fig.15 - 15h is a portion of an example of a load-bearing structure 10 without extensions or supports, such as those described and Figure 1a and 2a A portion of the example shown, or other portions not described above, may also include a lightweight polymer core 10a having a width 12. The load-bearing structure 10 may also include at least one polymer sheet as described above, such as the polymer sheets 67, 68 shown, and may also include at least one sealing member 70 or 80 for sealing the edges of the polymer sheets 67, 68 to each other and / or to seal the polymer sheets 67, 68 to the polymer core 10a, as can be illustrated. In general, the sealing of the polymer sheets to the polymer core and / or the sealing between the polymer sheets can be performed in a manner equivalent to and / or similar to any load-bearing structure and / or box described herein.

[0232] Fig.12 and15 An embodiment of a load-bearing structure 10 is shown having a first polymer sheet 67 and a second polymer sheet 68, wherein the first polymer sheet 67 and the second polymer sheet 68 may be adjacent to each other at an abutment 69. The abutment 69 may generally be formed by edges 67c, 68c of the polymer sheets 67, 68, respectively, and may be a smooth seam or may include some gaps and / or irregularities, for example, resulting from the manufacturing and / or connection process of bonding the polymer sheets 67, 68 to the polymer core 10a as described above. Fig.12 and 15 As shown, in some embodiments, a sealing feature 80 can be used to seal and / or cover the boundary 69 between the two polymer sheets 67, 68. The sealing feature 80 can generally cover and / or fill any gaps and / or bumps present at the seam, and can also generally extend a given amount over each polymer sheet 67, 68, for example, to form a more robust and / or durable seal. In general, the sealing feature covering the boundary 69 is as shown in FIG. Fig.12 and 15 The illustrated sealing member 80 can likewise be applied after the polymer sheets 67, 68 are bonded to the polymer core 10, as the sealing member 80 is located atop the polymer sheets 67, 68. Sealing members suitable for such an application can include any of the sealing members described above, for example, a sealing tape that can include a bonding surface on one side of the tape.

[0233] The sealing member may also be located between the sheets 67, 68 at the edges, similar to Fig.12e and 15e The sealing member 70 shown in FIG. The sealing member 70 may be any of the above-mentioned sealing members, for example, a double-sided adhesive sealing tape, a sealing liquid, a sealing compound, a mechanical and / or heat seal that may include an ultrasonic seal.

[0234] In other embodiments, Fig.12a , 12b , 15a and 15b, the load-bearing structure 10 may include a single polymer sheet 67, wherein the polymer sheet 67 may be provided throughout the entire thickness portion 14a ( Figure 1 and 1a ) or even Fig.12a and 15a As shown, the core may extend to some portion of the top surface 16 of the core, or may abut at a width portion 12 of the polymer core 10a, such as Figure 12b and 15bThe edge 67a or 67b of the polymer sheet 67 may be sealed to the polymer core 10a by a sealing member 70, wherein the sealing member 70 may be as shown. Fig.12a , 12b , 15a and 15b are placed between the polymer sheet 67 and the polymer core 10a. For example, the sealing member 70 can be applied to the polymer core 10a before bonding the polymer sheet 67. For another example, the sealing member 70 can also be applied to the polymer sheet 67 and bonded to the polymer core 10a at the same time as the polymer sheet 67. In another embodiment, the sealing member 70 can be applied between the edges 67a, 67b of the polymer sheet 67 and the polymer core 10a after the polymer sheet 67 has been bonded to the polymer core 10a. For example, the sealing member 70 can include a sealing liquid, a chemical sealing composition, an adhesive tape, etc. as described above, and can be inserted, injected, pressed into and / or otherwise placed between the polymer sheet 67 and the polymer core 10a. In another example, the sealing member can be provided by heat sealing, or can be an ultrasonic sealing device.

[0235] Still in other embodiments, such as Fig.12c , 12d , 15c and 15d, the load-bearing structure 10 having a single polymer sheet 67 can be as shown in Fig.12c and 15c As shown, the polymer core 10a is adjacent at a width 12, or as shown Fig.12d and 15d It is shown wrapped around the width 12 of the polymer core 10a. Fig.12d and 12c Alternatively, the edges 67a, 67b of the polymer sheets 67 in 15d and 15c, respectively, may be smooth seams, or they may include some gaps and / or irregularities, for example, resulting from the manufacturing and / or connection process of bonding the polymer sheet 67 to the polymer core 10a. Thereafter, a sealing member 80 may be used to seal and / or cover the edges 67a, 67b of the polymer sheet 67 and extend over the polymer core 10a. The sealing member 80 may generally cover and / or fill any gaps and / or irregularities that may exist at the seams, and may also generally extend a given amount over the polymer sheet 67, for example to create a more robust and / or durable seal. In general, a sealing member such as a sealing member covering the edges of the polymer sheet and a portion of the polymer core 10a may be used to seal and / or cover the edges 67a, 67b of the polymer sheet 67 and extend over the polymer core 10a. Fig.12c , 12d, 15c and 15d can be applied after the polymer sheet 67 is bonded to the polymer core 10, as the sealing member 80 is located on top of the polymer sheet 67. The sealing member can include any of the sealing members described above, such as a single-sided adhesive tape.

[0236] Fig.12e and 15e An embodiment of a load-bearing structure 10 having a first polymer sheet 67 and a second polymer sheet 68 is shown, wherein the first polymer sheet 67 and the second polymer sheet 68 may be adjacent to each other at a junction 69. The junction 69 may generally be formed by edges 67c, 68c of the polymer sheets 67, 68, respectively, and may be a smooth seam, or it may include some gaps and / or irregularities, for example, which are caused by the manufacturing and / or connection process of bonding the polymer sheets 67, 68 to the polymer core 10a. In some embodiments, as shown in FIG. Fig.12e and 15e As shown, the sealing member 80 can be used to seal the edges 67c, 68c to the polymer core 10a at the junction 69 between the two polymer sheets 67, 68. The sealing member 80 can generally cover and / or fill any gaps and / or bumps that may exist at the seam, and can also generally extend a given amount between the polymer sheets 67, 68 and the polymer core 10a. The polymer sheets 67, 68 can also be pressed into the sealing member 80 at the edges 67c, 68c, for example, to help fill any gaps and / or bumps at the junction 69. Typically, the sealing member below the junction 69 (such as Fig.12e and 15e The sealing member 80 shown in the figure can be applied after the polymer sheets 67, 68 are bonded to the polymer core 10a because the sealing member 80 is located below the polymer sheets 67, 68. The sealing member 80 can also include a sealing liquid, a sealing composition or a sealing tape, and in another example, it can also be inserted, injected, pressed and / or otherwise placed between the polymer sheets 67, 68 and the polymer core 10a after the polymer sheets 67, 68 are bonded to the polymer core 10a. In still another example, the sealing member 80 can also be applied to one or both of the polymer packages 67, 68 before bonding, and thereby bonded to the polymer core 10a simultaneously with the polymer sheets 67, 68. The sealing member can include any of the sealing members described above, for example, a double-sided adhesive tape, a sealing liquid, a chemical sealing composition, a seal produced by a mechanical and / or heat sealing device including an ultrasonic sealing device.

[0237] Fig.12f and 15fAn embodiment of a load-bearing structure 10 is shown having a first polymer sheet 67 and a second polymer sheet 68, wherein the first polymer sheet 67 and the second polymer sheet 68 can be connected to each other at an overlap 69'. Overlap 69' can be generally formed by overlapping one of the edges 67c, 68c of the polymer sheets 67, 68 with the other, as shown by edge 68c located on top of edge 67c, and can be produced, for example, by the second polymer sheet being bonded to the polymer core 10a after the first polymer sheet. In some embodiments, as shown in FIG. Fig.12f and 15f As shown, the sealing member can be used to seal the edge of the polymer sheet to the polymer core 10a, and / or seal one edge of the polymer sheet to another edge of the polymer sheet, for example, as shown, the edge 67c is sealed to the polymer core 10a and the edges 67c, 68c are sealed to each other. The sealing member 70 can generally cover and / or fill any gaps and / or bumps that may exist at the overlap 69', and can also generally extend a given amount below one of the polymer sheets 67, 68 and / or on top of the polymer sheets 67, 69. The polymer sheets 67, 68 can also be pressed into the sealing member 70 at the edges 67c, 68c, for example to help fill any gaps and / or bumps at the overlap 69'. Figure 12g and 15g The sealing member 80 in the embodiment can be applied after one polymer sheet is bonded to the polymer core 10a and before the second polymer sheet is bonded. The sealing member 80 can also be bonded to a polymer sheet and applied together with it, for example, by applying the sealing member 80 to the edge of the polymer sheet 68 before bonding the polymer sheet 68 to the polymer core 10a and the polymer sheet 67, wherein the polymer sheet 67 can be bonded before the polymer sheet 68. In still another example, the sealing member 80 can also be inserted, injected, pressed into and / or otherwise placed between the polymer sheets 67, 68 and the polymer core 10a after the polymer sheets 67, 68 are bonded to the polymer core 10a. The sealing member may or may not be activatable at the temperature and / or pressure of bonding the plate 67 or 68 to the core 10a as described above.

[0238] In another embodiment, Figure 12f-1 15h, sealing member 70 is present between the overlapping portion 69' of plate 67,68. This sealing member 70 can be any one of the sealing members described above. For the double-sided adhesive tape, it can be applied before the second plate 68 is bonded to the core and the first plate usually, and this adhesive can be activated in the bonding process. This adhesive can be applied to the edge of a side of the second adhesive tape that will be bonded to the core. For sealing liquid, it can be coated after the bonding process.

[0239] Figure 12g and 15g An embodiment of a load-bearing structure 10 is shown having a first polymer sheet 67 and a second polymer sheet 68, wherein the first polymer sheet 67 and the second polymer sheet 68 can be connected to each other at an overlap 69'. Overlap 69' can be generally formed by overlapping one of the edges 67c, 68c of the polymer sheets 67, 68 with the other, as shown by edge 68c located on top of edge 67c, and can be produced, for example, by the second polymer sheet being bonded to the polymer core 10a after the first polymer sheet. In some embodiments, as shown in FIG. Figure 12g and 15g As shown, sealing member 80 can be used to seal the edges of the polymer sheets to each other, as shown by sealing edges 67c, 68c to each other. Sealing member 80 can generally cover and / or fill any gaps and / or irregularities that may exist at overlap 69', and can also generally extend a given amount on top of polymer sheets 67, 68. Figure 12g and 15g The sealing member 70 shown in can be applied after the polymer sheet is bonded to the polymer core 10a, because the sealing member 80 is located on top of the overlap 69'. The sealing member may or may not be activatable at the temperature and / or pressure at which the plate 67 or 68 is bonded to the core 10a as described above. The sealing liquid can be contained in a bottle or box with a dispensing tip or dispensing end. The liquid can be dispensed into the edge where the edge of the polymer sheet contacts the surface of the core, or the edge of one thermoplastic plate contacts the edge of a second thermoplastic plate after the load-bearing structure is made. As previously described, the sealing liquid can be a solvent suitable for the core 10a and / or the thermoplastic plate 67 or 68, and can slightly dissolve the material near the surface of the core 10a or the membrane 67 or 68.

[0240] Still in other embodiments, such as Fig.14eAs shown, the load-bearing structure 10 has polymer sheets 67, 68, and the polymer sheet 68 can cover the top of the polymer core 10a. The edge 68c of the polymer sheet 68 can overlap the edge of the plate 67 (not shown here) to form a relatively smooth seam, or it can be flattened with some gaps and / or bumps, for example, these gaps and / or bumps can be caused by the manufacturing and / or connection process of bonding the polymer sheet 68 to the polymer core 10a of the polymer sheet 67. Thereafter, a sealing member can be used to seal and / or cover the edge 68c of the polymer sheet 68 and / or extend over the polymer core 10a as described above. The sealing member can cover and / or fill any gaps and / or bumps that may exist at the seam, and can also generally extend a given amount over the polymer sheet 67 and / or the polymer core 10a, for example to produce a more solid and / or durable sealing effect. Typically, a sealing member covering the polymer sheet edge whether there is an overlap 69a, and which may be part of the polymer core 10a, may be applied after the polymer sheets 67, 68 are bonded to the polymer core 10a, since the sealing member is located on top of the polymer sheet 68. The sealing member may include any of the sealing members described above, for example, a single-sided adhesive tape.

[0241] also, Fig.14e There may be an indentation in the polymer core 10a from the bottom edge or portion of the width near the bottom edge to accommodate an edge protector 11' as shown in 26a. The indentation may not be visible if the edge protector is located between the core and the polymer sheet or plate.

[0242] Sealing liquid can be applied like sealing members 70, 80 described above, and can be applied before or after polymer sheet is bonded to polymer core. The sealing liquid can also be applied on polymer sheet. If liquid is applied before film 67 or 68 is bonded to core 10a or film 67 or 68 is bonded to each other, then the sealing liquid can be activated under the temperature and / or pressure of plate 67 or 68 bonded to core 10a described above. In certain embodiments, as described above, sealing liquid can also be injected into below polymer sheet after completing bonding of plate 67 or 68 to core and / or bonding of plate 67 or 68 to each other, and thus can be activated without the temperature and / or pressure of plate 67 or 68 bonded to core 10a described above. Fig.13 and 13a An example is shown in which a sealing liquid is injected under a polymer sheet 68 that has been bonded to a polymer core 10a. Fig.13The overlap between the plates 67, 68 (not visible here) is shown, and a sealing liquid is being injected under the edge 68c using a syringe 50, thereby bonding the edge 68c to the edge of the plate 67 and / or a portion of the polymer core 10a. The edge 68c can then be pressed down, such as by hand or using a press and / or pressing device, such as Fig.13a , for example, to reduce any bumps and / or gaps at edge 68c and / or to create a more continuous seal.

[0243] The sealing compound can exist in the form of a treated solid or natural liquid, or even in the form of a suspension, and the sealing compound can usually be applied to the edge of the polymer sheet before it is bonded to the core, and its sealing performance can usually be activated during the bonding process as described above. In one embodiment, the compound in liquid form can be encapsulated in a capsule. The capsules do not adhere to each other, so that they can enter in a free-flowing form. However, the capsules may be adsorbed or attracted to the surface of the film or polymer sheet, so that they can be applied, for example, by spraying on the surface to be sealed before the bonding process. The composition can be activated by heating and / or pressure during the process of bonding the core to the board. In another embodiment, the compound can be directly applied in liquid form, similar to the application of the sealing liquid described above, and the compound may or may not need to be activated at the temperature and / or pressure of bonding the plate 67 or 68 to the core 10a described above. For example, as described above, the liquid compound can also be mixed with polymer particles to form a suspension. In this embodiment, when the polymer sheet is made of high-impact polystyrene, the powder is polystyrene that has become powdered. The sealing liquid may be relatively non-volatile, such that the liquid does not substantially evaporate prior to the bonding process of the board to the core and / or the board. The chemical sealing composition may also include a self-recovering and / or self-healing composition. Such compositions are desirable because the sealing member may be subject to high pressure, high damage and / or high wear, and it may be possible to increase the efficiency and / or service life of the load-bearing structure by using a self-recovering / self-healing material.

[0244] When a sealing tape is used, the tape may include one side with a contact or tacky adhesive and another side with a heat activated adhesive. The tacky or contact adhesive side may be covered by a liner, and the tape may be as Fig.14 Afterwards, the roll 63 of the tape 60 can be unwound manually or by a tape dispenser and the liner 61 can be removed to reveal the Fig.14a as well as Figure 14a-1The adhesive or contact adhesive surface 62 is shown in the example of the tape dispenser 30 in FIG. The tape 60 shown can be a double-sided adhesive tape or a single-sided adhesive tape and can include a liner that can then serve as a sealing member such as a sealing member 70, 80 and is applied to the edge of the polymer sheet and / or the polymer core as described above and shown with the tape 60, wherein the tape 60 is applied on the polymer sheet 67 and the polymer core 10a while the liner 61 is being removed to expose Fig.14b and 14c In some embodiments, the tape 60 may be double-sided, while in other embodiments, the tape 60 may be one-sided, such as Fig.14d The tape 60 in the embodiment of the present invention can be applied over the bonding seam.

[0245] On the other hand, the heat activated adhesive can include a hot melt adhesive, a thermosetting adhesive, or a reactive adhesive. The heat activated adhesive can be selectively activated at the temperature during the bonding process.

[0246] In some embodiments, the sealing members 70, 80 may include a self-recovery and / or self-repairing composition as described above. This composition is expected to be used because the sealing members 70, 80 may be present in high pressure, high damage and / or high wear, and it can increase the efficiency and / or service life of the load-bearing structure by using self-recovery / self-repairing materials. For example, some polymers can recover and / or repair tearing and / or other damage by contact repolymerization and / or contact adhesion of the adjacent edges of the polymeric material. These polymers may include, for example, polymers that repolymerize with each other when exposed to ultraviolet rays and / or other electromagnetic radiation and / or heat. For example, polyurethane-deacetylated chitosan mixed polymers can be repolymerized using ultraviolet rays to restore tearing and / or other discontinuities. For another example, a new class of polymers can also be used, which is formed from the condensation reaction between paraformaldehyde and 4,4'-diaminodiphenyl ether developed by IBM. As described above, any one of the various sealing members described herein may include a self-recovery and / or self-repairing composition.

[0247] In other embodiments, the sealing members 70, 80 may include melting, welding, sintering, and / or other heating / pressurization connections of materials in polymer sheets (such as polymer sheets 67, 68 and / or polymer core 10a). For example, the edges of the polymer sheets may be melted and / or connected together, and / or the edges of the polymer sheets and the polymer core 10a may be melted and / or connected together by local heating using ultrasonic welding. The connection area may be subjected to pressure.

[0248] In some embodiments, Figure 12h-12m As shown, the polymer sheets may be folded over each other at the seam. The seam may also be subjected to heat, pressure, and / or vacuum to help connect the polymer sheets together at the fold and / or to bond the polymer sheets to the polymer core. In one embodiment, a stopper may be used to hold at least one polymer sheet and / or the polymer core in place to achieve folding and sealing of the polymer sheets, such as Figure 12h 40. The polymer core 10a can be inserted into the first polymer sheet 67 that rests on the stop 40. For example, the first polymer sheet 67 has sufficient rigidity at this stage to remain substantially vertical during the bonding process until it is subjected to additional heat, pressure and / or mechanical force to cause folding. For example, when the first polymer sheet 67 is being bonded to the polymer core 10a (not shown), it can be fixed in place vertically so that the polymer sheet is in a suitable vertical orientation at its edge when it cools and regains rigidity. In some embodiments, as Figure 12h As shown, the polymer core 10a may also include a chamfer 12', which may be beveled at about 45 degrees, for example (for another example) to help fold the polymer sheet. A second polymer sheet 68 may be placed on the polymer core 10a and may also cover the vertical edge of the first polymer sheet 67 to form Fig.12i The enclosed area 45 is shown. The second polymer sheet 68 can also be fixed to the stop device 40 at the edge 68d, for example, to help fix the polymer sheet 68 in place during folding. Once the polymer sheets 67, 68 are positioned, they can be folded over each other, such as Fig.12j For example, the end 67d of the polymer sheet 67 can be folded toward the beveled edge 12', while the fold 68e of the polymer sheet 68 can be folded into the closed area 45. This folding operation can be assisted by heating the polymer sheets 67, 68, applying pressure and / or mechanical force to the area, and / or applying a vacuum, for example, to the closed area 45. Once the folding is completed, as shown in FIG. Fig.12 K, heat and / or pressure may be used to seal the fold, for example, so that the polymer sheets 67, 68 may be bonded together, for example, by melting, welding, and / or otherwise adhering to each other. An adhesive similar to a heat-activated adhesive may also be present in the region and activated by heating the fold to help create a sealed seam. Excess material of the polymer sheet 68 is then trimmed away, leaving a portion of the polymer sheet 68 as shown. Figure 12l The cut-off edge shown can be away from the load-bearing area. Figure 12m As shown in the close-up view in , the completed seam can thus include, for example, a polymer sheet 67 sandwiched between two polymer sheets 68 at the beveled edge 12', and a cut edge 68f away from the seam. These edges can also be joined with a sealing member to improve the joining defects described above.

[0249] In some embodiments, the support structure 10 may also include grooves, valleys and / or other topographic features to indicate where the polymer sheet can be trimmed and / or cut, such as Fig.25 12d in the embodiment of the present invention. The groove 12d may be present around the entire circumference of the width 12, for example, so that there is a contour feature to guide the trimming of the polymer sheet. This may be desirable, for example, where there may only be one polymer sheet bonded to the polymer core, and the edge of the polymer sheet may thus be trimmed shorter than the load-bearing surface 16 so that the edge does not cover a portion of the load-bearing surface 16, so that the edge of the polymer sheet may not catch cargo when loaded and / or unloaded.

[0250] In some embodiments, as described above, including but not limited to, for example Fig.26 and 26a The edge protectors shown may also be used on the load-bearing structure. In one aspect of the invention, when cargo is loaded on the load-bearing structure, for example, the cargo may be secured in place on its surface by cargo securings such as straps, tiedowns, anchors, cables and / or other items. In a typical embodiment, the load-bearing structure may be reinforced with protectors 11 or 11' continuously or at locations such as where cargo securings contact or wrap around the load-bearing structure in a predetermined area or at any location on the load-bearing structure. In some embodiments, the protectors may be edge protectors that may be located approximately at the circumference of the load-bearing structure. This may be desirable, for example, because when cargo securings are used, the bottom edge and portions of the width near the bottom edge of the load-bearing structure typically bear a significant amount of the force of the cargo securings. In some embodiments, the protectors may be present at intervals at predetermined locations on the load-bearing structure 10, such as with recesses 12b and edge protectors 11. Fig.25As shown, reinforcement may be needed at this point. For example, the protectors can distribute the forces and / or pressures from cargo restraints across a larger area on the load-bearing structure and / or reinforce the area where the cargo restraints are located. For example, the protectors can also be harder than the underlying portion of the load-bearing structure, which, for another example, can better distribute the forces on the load-bearing structure without causing significant deflection, deformation or damage. In other embodiments, the protectors can be present around the entire circumference of the load-bearing structure, rather than appearing at intervals. Cargo restraints can be used at these same predetermined locations or other locations to help keep the cargo in place. Fig.24 An embodiment of a load bearing structure is shown, which may generally include a top side 16, where cargo may be loaded (not shown), and a width 12, which may be vertical or substantially perpendicular to the top side 16. In some embodiments, the load bearing structure 10 may also be used with edge protection. Fig.24 A load-bearing structure 10 is shown, wherein the load-bearing structure may include a plurality of depressions 12b along a width 12 where edge protectors may be placed. Generally, depressions 12b may be sized to accommodate edge protectors, for example, such that the edge protectors are flush with the surface of width 12. Depressions 12b may be placed at regular and / or predetermined intervals about width 12 and may generally be located where cargo securing objects may contact load-bearing structure 10. In some embodiments, such as Fig.24a As shown, the bottom side of the load-bearing structure 10 may include a channel 13 in which cargo securing items may be placed. As shown, the recess 12b may thus be located at the end of the channel 13. Figure 24b and 24c As shown, the recess 12b may generally have an end edge 12c. In other embodiments, the load-bearing structure 10 may include the recess 12b, and as shown in FIG. Fig.24d and 24e As shown, the bottom side of the load bearing structure 10 may not include the channel 13. The rim 12c may be slightly more visible than the remainder of the recess 12c and may help position the recess 12b and / or edge protector in the proper location.

[0251] Fig.25 An example of a load bearing structure 10 is shown having edge protectors 11 in place at recesses 12b as described above.

[0252] As described above, end edges 12c of depressions 12b may be present on polymeric core 10a, and edge protectors may be placed in depressions 12b between end edges 12c so that they are flush or substantially flush with the remainder of polymeric core 10a. The protectors may or may not be readily visible and / or discernible after covering with a polymeric film or sheet. If the protectors are not themselves visible or discernible when in position on polymeric core 10a, then there may be indicators, such as, for example, visible lines of end edges 12c and / or discernible by tactile inspection of fine indentations.

[0253] In some embodiments, the edge protector may have an L-shaped cross-section, such as Fig.26 1 and 12. The L-shaped end protector 11 having an outer surface 11a and an inner surface 11b is shown in FIG. 1 , wherein the outer surface 11a can, for example, contact a cargo securing item, and the inner surface 11b can contact the recess 12b. The L-shaped edge protector 11 can be present at intervals or continuously at the bottom and around the width of the core in a certain manner, wherein the manner refers to the L-shaped edge protector 11 encapsulating a portion of the bottom side near the outer edge, wrapping around the edge and extending to cover a portion of the width near the bottom side, such as Fig.25a The partial interface diagram of the middle load-bearing structure 10 is shown in this figure, in which the L-shaped edge protector 11 is located in the recess 12b on the core 10a.

[0254] In other embodiments, the edge protector may have a substantially C-shaped cross-section, such as Fig.26a As shown in the figure, a C-shaped end protector 11' having an outer surface 11a and an inner surface 11b, wherein the outer surface 11a can, for example, contact a cargo securing item, and the inner surface 11b can contact the recess 12b. The C-shaped edge protector 11' can be present in a certain manner, either intermittently or continuously, around the bottom, width, and top of the core, wherein the manner refers to the C-shaped edge protector 11' encapsulating a portion of the bottom side near the outer edge to wrap around the edge and extend to cover the width and a portion of the top side near the width, such as Fig.25b1 is a partial cross-sectional schematic diagram of the load-bearing structure 10 in which a C-shaped edge protector 11' is wrapped around the width 12 and is seated in the recess 12b. According to another embodiment, the edge protectors may exist in pairs, wherein each edge protector has a substantially L-shaped cross-section and may be present around the bottom, width and top of the core at intervals or continuously in a certain manner, wherein the manner is that one of each pair of protectors will encapsulate a portion of the bottom side near the outer edge to be wrapped around a portion of the edge, while the other extends to cover a portion of the width near the top side and a portion of the top side near the width, which may then appear in a similar form to the C-shaped edge protector 11'. Each pair of protectors may or may not be sufficient when placed on the load-bearing structure 10. In other embodiments, the load-bearing structure 10 may include separate recesses for the upper and lower edges of the width 12, such as Fig.25c A partial cross-sectional schematic diagram of the middle load-bearing structure 10 is shown in this figure, in which there are an upper recess 12b-1 and a lower recess 12b, and edge protectors 11-1 and 11, wherein the edge protectors 11-1 and 11 are respectively located in separate portions 12e of the width 12, and the separate portions of the width 12 are exposed between the edge protectors 11 and 11-1.

[0255] In some embodiments, the edge protector is Fig. 27 and 27a As shown, the edge guard 11 '' may also include guides and / or other components for fixing the cargo fixings. As shown, the edge guard 11 '' may include guides 11c, which can be used to guide and keep the cargo fixings in place, such as Fig.27a 4 and 5. The belts shown in FIG. 4 secure cargo 490 to the load bearing structure 10. This may be desirable, for example, to help prevent the belts from lateral movement or slipping. The guides 11c may also protrude and help the edge guards 11" to be visible so that cargo securing objects can be positioned above the edge guards.

[0256] In some embodiments, the protective body may be present on the core before the polymer sheet covers the core as described above. Figure 24-26a As shown, the core may be machined with indentations to accommodate the protector so that the protector is flush with the core, thereby allowing the plate to cover the core with the protector as if the protector were not there. On the other hand, the core may be machined with indentations but not deep enough to accommodate the entire thickness of the protector so that after covering with the plate, there may be a small protrusion where the protector is present. Fig. 27 and 27a The middle edge protector 11 ″ sticking out as a protrusion is a good example. In another embodiment, the protector can be added after covering the core with a polymer sheet or board.

[0257] The protector may be made of any polymeric or metallic material, or combination thereof, which may be easily molded or cast into the desired shape and which is rigid or substantially rigid or has a sufficient reinforcing effect on the edge. In one embodiment, when the protector is present on the core before covering the core with a polymer sheet or board, the protector may be made of the same material or a material having similar bonding properties to the board so that the protector bonds to the board and / or to the core at the temperature at which the board is bonded to the core. This may be further desirable because the load-bearing structure may be more conveniently and / or more easily recycled when it is substantially composed of a single material. When the edge protector is located on the core, if the edge protector is not made of a similar material or the edge protector is not bonded or adhered to one or more polymer sheets, the outer edges of the sheets may be bonded to the edge protector using a sealing member, and the one or more polymer sheets may or may not be bonded or adhered to the edge protector.

[0258] In another embodiment, any material may be used for the protector when the protector is attached to the load-bearing structure after one or more sheets are bonded to the core.

[0259] In addition to materials that are the same or similar to the polymer sheet, suitable materials for edge protectors, especially those that are present on the load-bearing structure after the core is bonded to a single panel or multiple panels, can include any metal and polymeric material as long as such material can be manufactured into a rigid or substantially rigid part. Examples of suitable materials may include, but are not limited to, for example, polymers that can be molded, thermoformed, or cast. Suitable polymers include polyethylene; polypropylene; polybutylene; polystyrene; polyesters; polytetrafluoroethylene (PTFE); acrylic polymers; polyvinyl chloride; acetal condensation polymers such as polyoxymethylene or polyoxymethylene resins (available from DuPont); natural or synthetic rubbers; polyamides, or other high temperature polymers such as polyetherimides such as ULTEM®, polymer alloys such as Lexan® resins, thermoplastic polycarbonate (Lexan®) plastics, which are composites of polycarbonate and polybutylene terephthalate fibers, and thermoplastic polycarbonate (Lexan®) plastics, which are composites of polycarbonate and isophthalate terephthalate resorcinol resins (all available from General Electric Plastics (GE Plastics) Plastic) obtained); liquid crystal polymers, such as aromatic polyesters or aromatic polyester amides, polyester imine anhydrides or combinations thereof, wherein the components of the aromatic polyester or aromatic polyester amide contain at least one compound selected from aromatic hydroxyhydroxy acids (such as hydroxybenzoates (rigid monomers), hydroxynaphthoates (elastic monomers)), aromatic hydroxyamines and aromatic diamine combinations (as exemplified by U.S. Pat. Nos. 6,242,063, 6,274,242, 6,643,552 and 6,797,198, the contents of which are incorporated herein by reference), and polyester imine anhydrides have terminal anhydride groups or lateral anhydrides (as exemplified by U.S. Pat. No. 6,730,377, the contents of which are incorporated herein by reference). Some of these materials are recyclable or are made to be recyclable. Fermentable or biodegradable materials may also be used, and may include any biodegradable or biofermentable polyesters, such as polylactic acid resins (including L-lactic acid and D-lactic acid) and polyacetic acid (PGA), polyhydroxyvaleric acid / hydroxybutyric acid resins (polyhydroxybutyrate (PHBV)) (copolymers of 3-hydroxybutyric acid and 3-hydroxyvaleric acid) and polyhydroxyalkanoate (PHA) copolymers, and polyester / polyurethane.Some non-fermentable or non-biodegradable materials can also be processed to be fermentable or biodegradable by adding specific additives, for example, any of the oxo-biodegradable additives such as D2W™ provided by Symphony Environmental, Borehamwood, United Kingdom and TDPA® manufactured by EPI Environmental Products Inc. Vancouver, British Columbia, Canada.

[0260] In addition, any polymer composite material, such as engineered prepreg or composite material, may be used, where the polymer is filled with pigments, carbon particles, silica, glass fibers, or mixtures thereof. For example, a mixture of polycarbonate and ABS (acrylonitrile-butadiene-styrene) may be used. For another example, carbon fiber and / or glass fiber reinforced plastics may also be used.

[0261] Applicable metals or metal materials may include metals and metal alloys, such as aluminum, steel, stainless steel, nickel-titanium alloy, etc.

[0262] To help retain the protector to the core prior to and during the bonding process, an adhesive or double-sided adhesive tape may be used. This may be desirable, for example, because the protector may not be sufficiently adhered and / or clamped to the load-bearing structure prior to the bonding process. Examples of adhesives may include pressure-sensitive adhesives, such as hot melt pressure-sensitive adhesives or non-hot melt pressure-sensitive adhesives. Examples of double-sided adhesive tapes may include double-sided adhesive pressure-sensitive adhesive tapes, such as double-sided hot pressure-sensitive tapes or double-sided non-hot melt pressure-sensitive tapes. The thickness of the adhesive or tape may be very thin, so that the adhesive or tape does not substantially increase the thickness of the edge protector and / or does not prevent the edge protector from significantly protruding from the surface of the load-bearing structure. In some embodiments, the adhesive or tape may be substantially melted during the bonding process. The amount of adhesive or tape may also be minimal so that it does not significantly affect the overall material composition of the load-bearing structure, which may be desirable because the load-bearing structure can be more conveniently and / or more easily recycled when it is substantially composed of a single material.

[0263] In other embodiments, the protector may utilize friction fits, roughened and / or textured contact surfaces, and / or other mechanical means to attach and / or secure it in place on the load-bearing structure.

[0264] To keep the edge protectors securely in place once they are present after the bonding process, a structural adhesive (such as that used in edge seals described above or below) may be used so that the edge protectors do not separate or move around during or after bundling, thereby keeping the cargo in place.

[0265] The protector can be of any thickness as long as it provides the desired reinforcement to the edge. Because some materials are more rigid than others, a thinner protector may be sufficiently rigid. For more flexible materials, a thicker part may be required to provide sufficient rigidity.

[0266] The edge protectors can be manufactured by molding or casting. In one embodiment, the edge protectors can be manufactured in batches and then cut to the desired size. In another embodiment, the edge protectors can be individually machined to the desired size. A generally L-shaped edge protector and a generally C-shaped edge protector 11 ' may also be desirable because the continuous cross-sectional shape allows it to be formed into a continuous length by extrusion, which can be cut into the desired shape.

[0267] The load-bearing structure of the present invention, which may be a pad platform or box, may have antimicrobial properties, as described above. An antimicrobial agent is a drug that actively resists one or more organisms, including bacteria, viruses, fungi, protozoa, parasites, and larvae. A foreign host is a bacteria, pathogen, or organism that can be transported on the surface of the load-bearing structure. The antimicrobial drug may be in powder form or in liquid form.

[0268] In an exemplary embodiment, an antimicrobial drug that can eliminate, prevent, retard or minimize the growth of bacteria can be placed on an exposed surface, e.g. Figure 1 The top side 16 , the width 12 a and / or the bottom side 18 of the support structure 10 are shown in FIG.

[0269] In any embodiment, when at least one antimicrobial is added to the material used to make the polymer sheet of the board as described above, or at least one antimicrobial with some surface activity is coated on the exposed surface of the polymer sheet of the board as described above, the material including the chemical antimicrobial material or compound can produce antimicrobial properties, and the chemical antimicrobial material or compound can be permanently bonded for a certain period of time such as the service life of the load-bearing structure; or when at least one antimicrobial is coated on the polymer sheet of the board as described above with the help of a coating agent, it can maintain its antimicrobial effect. In one embodiment, the chemical can be deposited on the surface of the load-bearing structure by covalent bonding.

[0270] When one or more antimicrobial agents are incorporated into the material used to make the polymer layer (e.g., sheet), the one or more agents can be dispersed into the material directly or with the aid of a suitable carrier, such as an adhesive, a solvent, or a suitable polymer mixing aid. These carriers can also be useful for the above-mentioned coating aids. Effective adhesives refer to those adhesives that do not affect the antimicrobial activity of the antimicrobial agent. In one embodiment, when the antimicrobial agent is incorporated into the material used to make the polymer layer (e.g., sheet), the antimicrobial agent can be a masterbatch in the material, or a carrier with a higher density before being added to the material used to make the polymer layer (e.g., sheet) in a desired proportion. In another embodiment, the antimicrobial agent can be directly added to the material used to make the polymer layer (e.g., sheet) without an intermediate step.

[0271] In other embodiments, the antimicrobial agent in the coating or incorporated into the material used to make the polymer layer may include chemical antimicrobial materials or compounds that can be configured in a non-permanent manner so that they can slowly dissolve, slowly leach, or otherwise release antimicrobial substances during use. When at least one antimicrobial agent is added to the material used to make the above-mentioned polymer layer, or when at least one antimicrobial agent is applied to the exposed surface of the polymer layer (such as the above-mentioned sheet), the material can be fully bound, although temporarily and / or in sufficient amounts to last for at least a period of time (such as the service life of the load-bearing structure); or when at least one antimicrobial agent is applied to the exposed surface of the polymer layer (such as the above-mentioned sheet) with the help of a coating agent, their antimicrobial effect is maintained. Suitable one or more agents are those that tend to migrate slowly to the surface or have no leaching (as defined in the present invention) to provide the surface with antimicrobial properties.

[0272] In other embodiments, the antimicrobial agent in the coating or incorporated into the material used to make the polymer layer may include a source of the antimicrobial agent that can leach and / or release the agent in a humid environment or when in contact with moisture. These sources can be incorporated into the matrix material used to make the polymer layer (such as the sheet material described above). Incorporation of these sources may be particularly suitable for polymer matrices.

[0273] Chemical antimicrobial materials or compounds may include a variety of substances including, but not limited to, antibiotics, antifungal agents, general antimicrobial agents, quaternary ammonium cations, metal ion sources such as metal ion generating materials, triclosan, chlorhexidine or any other material capable of producing an antimicrobial effect, and / or any other suitable compound or mixture thereof.

[0274] In another embodiment, antimicrobial activity can be obtained by utilizing the antimicrobial properties of various metals, especially transition metals that have little effect on the human body. Examples may include free silver ion sources, which are known for their antimicrobial effects and little biological effects on the human body. The antimicrobial activity of metal ions can be produced by a variety of methods, which may include, for example, mixing a metal ion source with a polymer layer (e.g., a sheet) during manufacturing, coating a surface by methods such as plasma deposition, loosely complexing a metal ion source by disintegrating the surface of a polymer layer (e.g., a coating or sheet) to form affinity or binding sites by methods such as etching or corona discharge, and configuring the metal to the surface by methods such as electroplating, photoreduction, and precipitation. The coated surface can then slowly release free metal ions that can produce an antimicrobial effect during use.

[0275] In some embodiments, a layer comprising a substantially non-permanent coating of an antimicrobial compound may be present on top of a substantially permanent coating comprising an antimicrobial compound.

[0276] The substantially permanent antimicrobial coating can be, for example, substantially flexible so that the coating substantially covers the working surface of the load-bearing structure during use, even when the structure is in a flexed state. If the antimicrobial compound is not capable of forming a substantially flexible coating by itself, a binder capable of forming a substantially flexible coating can be used to aid in the flexibility of the resulting coating.

[0277] A detailed description of antimicrobial coatings and agents may be found in US Patent Application No. 13 / 549,474, entitled "Load Bearing Structure Having Antimicrobial Properties," the contents of which are hereby incorporated by reference in their entirety.

[0278] The load-bearing structure may also include a plurality of bridges, runners, wear parts and / or connectors that may be attached to the second face of at least some of the extensions or supports 20-28 of all embodiments of the load-bearing structure described herein. The wear parts may typically be attached to the bottom of some of the plurality of supports so that they may protrude from the bottom of the supports and contribute to the durability of the supports. A detailed description of the wear parts may be found in U.S. Pat. Nos. 7,908,979 and 5,868,080, the contents of which are incorporated herein by reference.

[0279] These wear parts are similar to bridges or strips extending between adjacent extensions or supports. In some embodiments, there may be only one wear part. In other embodiments, two of these parts may be arranged in a cross shape. In other embodiments, each wear part may be attached to each pair of adjacent extensions or supports around the periphery of the load-bearing structure. In other embodiments, they may be connected to each pair of extensions or supports of the load-bearing structure.

[0280] Strips, bridges, and / or other connectors may also be included, such as connecting multiple supports, which generally increase the strength and / or rigidity of the matrix. Fig.21a An example of a cross bar 906 connecting multiple extensions or supports 904 is shown. Fig.21 An example of strips 926 connected in groups of three extensions or supports 924 along two edges is shown. Fig.21d An example of a strip 916 connecting three groups of extensions or supports 914 in a parallel manner is shown. In general, any desired combination of extensions or supports can be connected by a strip or bridge. The strip or bridge can be made of any suitable material. For example, the bridge can be made of wood, metal and / or various plastic materials, including those materials used to make the coating, including polyolefins, polyesters, lead-free PVC, etc. In some embodiments, the strip or bridge is made of HIPS (high impact polystyrene) by extrusion molding. In addition, the bridge can be configured so that each of them spans two or more supports in a row and can be attached to the ends of the supports to connect them to each other. For example, the bridge can be adhered using a suitable adhesive.

[0281] As described above, the strip or bridge may be attached to the bottom surface of the support member and may be partially flush with the bottom surface of the support member, for example, attached within a recess formed in the bottom surface of the support member, such as Fig.21c and 21d As shown, or protruding from the bottom surface of the support member, as shown Fig.21a As shown, thereby improve the wear resistance of support member.In addition, the bottom surface of strip or bridge member also can be roughened, to improve the anti-slip property of matrix.

[0282] As described above, for lightweight load-bearing structures, the core 10a is generally made of a foam material, such as a closed-cell foam core 10a, such as an expanded polystyrene core 10a, which is bonded to a polymer layer in an area adjacent to the surface by heating and / or pressing, and this polymer layer is, for example, a high-impact polymer sheet 67 (e.g., a polystyrene sheet).

[0283] The foam core 10a can be manufactured using a pre-produced bulk form, such as expanded polystyrene foam, which can be cut into desired shapes and sizes. Depending on the degree of expansion of the glass powder used to make the foam, the foam density can also be varied. The foam density can also determine the appropriate load or cargo to be loaded.

[0284] A typical foam core by itself may not have sufficient structural strength to serve as a load bearing platform unless it has a higher density, for example, the particles are not highly expanded. A pad platform of sufficient strength can be formed by combining the core 10a with a high impact polymer sheet 67 (eg, polystyrene board).

[0285] For any polymer core used, the polymer sheet or film may be selected to have better compatibility when bonded or combined with the polymer core. Generally, the film or sheet may comprise any polymer material capable of being formed into a sheet or film, and may include: acrylonitrile butadiene styrene; polyester; polystyrene; polycarbonate; PET; APET; PETG; lead-free PVC; copolyester / polycarbonate; and HDPE. For example, for polystyrene foam, a high-impact polystyrene sheet or film may meet the needs. In addition, the high-impact polystyrene sheet or film also exhibits high strength, allowing thinner sheets or films to be used.

[0286] As mentioned above, the component can also be made of the same or similar material as the covering film or sheet. This can also help the component to adhere to the film or sheet.

[0287] In one embodiment, the sheet 67 may include an antimicrobial agent that may be added to the material used to make the sheet 67. The antimicrobial agent may be in powder form or in liquid form. In another embodiment, at least one antimicrobial agent may be applied to the exposed surface 16 of the sheet 67. The antimicrobial agent may be in powder form or in liquid form. When the antimicrobial agent is applied, the application may be performed before the sheet 67 is combined with the core 10a or after the load-bearing structure 10 is manufactured.

[0288] The bonding may be effected by heating and / or pressurizing. In one specific example of a load-bearing structure, the bonding process may cause portions of the expanded polystyrene core 10a adjacent to the bottom surface 18 to be bonded to the high impact polystyrene sheet 67 by heating and pressurizing to form a reinforced polystyrene. In addition, a portion of the expanded polystyrene adjacent to the edge 12a and adjacent to the bottom surface 18 may be bonded to the high impact polystyrene by heating and pressurizing to form a reinforced polystyrene (if desired). A detailed description of this bonding process may be found in US Pat. No. 6,786,992, the contents of which are incorporated herein by reference in their entirety.

[0289] Another specific example of the load-bearing structure 10 is disclosed in US Pat. No. 7,908,979, International Application Publication No. WO04041516, and US Pat. No. 7,413,698, all of which are hereby incorporated by reference in their entirety.

[0290] In another exemplary embodiment, any of the above-mentioned load-bearing structures can be assembled into a box, and these load-bearing structures form any of the wall, top and bottom parts of the box, especially the bottom, such as Figure 8 , Figure 8A-8E As shown, the bottom has a plurality of support members extending from the bottom of the core 10a, and the side walls and the top may or may not include support members. Figure 1 , 1a , 2, 2a, 4, 5, 6, 7, 12, 12 a-f) include those having an antimicrobial coating capable of eliminating, preventing, delaying or minimizing bacterial growth, which antimicrobial coating may be present in the material used to make the polymer layer (e.g., a sheet) or coated on one or more exposed surfaces.

[0291] For example Fig. 9 The bottom structure of the box can also be made by combining the core 10a with the polymer sheet 67, as described above. Figure 1 , 1a , 2 and 2a. Fig.10 and 11 , a line drawing of an example of a load-bearing structure with a half shell 380 thereon is shown according to one embodiment of the present invention, wherein the half shell 380 is located on the load-bearing structure. Fig. 9 , the bearing structure 10a can be used as Fig.11 The bottom of the box has a top surface 115 and a rim 110. In this embodiment, the load-bearing structure 10a is shown with six (6) pockets 125 and two (2) slots or recesses 130 through the top surface 115, each of which can extend to the core 10a (not shown) of the pad platform 10. In one embodiment of the present invention, the pockets 125 can be used to locate the phase change material. In one embodiment of the present invention, the slots or recesses 130 can be used to locate one or more shells. Fig.11 A load bearing structure according to one embodiment of the invention is shown having a phase change material box or pocket 125a located in pocket 125 and having a half housing located on the load bearing structure. These boxes or pockets are shown here as being generally rectangular, but other shapes are possible.

[0292] like Fig. 9 As shown, in another embodiment, the bottom can also be as Figure 1a Or the same as shown in FIG. 2 a , but also with a groove 130 .

[0293] In another exemplary embodiment of the present invention, a detachable or foldable box for storage and / or transportation has a bottom, four walls extending from the bottom, and a top panel to form an outer shell, wherein the bottom, walls, and top panel all have an inner surface, an outer surface, a width connecting the inner surface and the outer surface, and four inner edges and four outer edges. The bottom, the four walls extending therefrom, and the top panel can be formed by the load-bearing structure of the present invention. When the box is folded or disassembled, the area occupied does not exceed the area of ​​the largest single component, such as Figure 8 , Figure 8A-8E In one embodiment of the present invention, the bottom, four walls and top each include a surface extending generally along no more than about 80% of the four inner edges of the walls, bottom and top of any box component, and the components on adjacent components have opposite interlocking components, such as Figure 8 , Figure 8A-8E As shown. That is, if the edge has a groove, the length of the groove is less than 80% of the length of the edge. In an alternative embodiment of the present invention, the bottom, four walls and top each include a surface extending generally along no more than about 90% of any four inner edges of the walls, bottom and top of the box components, and the components on adjacent components have relative interlocking components. That is, if the edge has a groove, the length of the groove is less than 90% of the length of the edge.

[0294] Relative interlocking members can also be defined as depressions on the box wall corresponding to the protrusions of the goods, so that the box "fits" with the goods without fasteners. The interlocking members can include respective depressions and protrusions on adjacent connecting parts. For example, when the members along one side have a containment characteristic, the members on the adjacent parts have a protruding characteristic, so that the interlocking members match to form the box without the help of additional clips or fasteners. The term "no fasteners required" means that the interlocking members are not interlocked by any part that is not the bottom, four walls or top. If necessary, additional fixing devices can be used to ensure that the box is more complete, and such additional fixing devices may include straps and / or heat shrink packaging. In one embodiment, each wall, top and bottom of the box can also be composed of a lightweight core that is substantially covered by a polymer layer (such as a high-impact sheet), which has antibacterial properties or is combined with at least one antibacterial agent therein or thereon, and a load-bearing structure having the above-mentioned width is formed by covering the polymer layer on at least one surface of the core. In another embodiment, a structural metal mesh may be inserted into the core to resist puncture of the surface, and each wall, top and bottom of the box may also be composed of a lightweight core substantially covered by a polymer layer (e.g., a high impact resistant sheet), which may or may not have antimicrobial properties or have at least one antimicrobial agent incorporated therein or thereon, by covering at least one surface of the core with a polymer layer to form a load-bearing structure having the above-mentioned width. Figure 8800 is shown in a perspective view after assembly, generally including a bottom 812, side panels 801, 802, 803 and 804, and a top 816. Generally, the box 800 can be assembled into Figure 8 The form shown does not require the use of adhesives, fasteners and / or other assembly aids, and can be assembled and maintained in a generally predetermined manner. In one embodiment, as Fig. 8A As shown, the bottom 812 can be generally rectangular and can include a plurality of channels or grooves 831, 832, 833, and 834, each adjacent to the edge of the bottom 812. Each groove 831, 832, 833, and 834 terminates at a substantially open corner to the edge, as shown in corners 812a, b, c, and d, so that at least one end of the groove is open to insert a side panel. Corners 812a, b, c, and d can also include closed edges, thereby acting as a stop, for example, one or more side panels can rest against the closed edge of the corner and be substantially retained within the corner and prevent the side panel from exceeding the corner. As shown in FIG. Figure 8B As shown, the side panels, such as side panel 801, may include corresponding ridges 841, which may slide into and be retained in corresponding grooves, such as groove 831 as shown. The side panels, such as side panel 801 as shown, may also include ridges 841a opposite to ridges 841, which may correspond to and be retained in the grooves of the top 816.

[0295] Typically, the side panels 801, 802, 803, and 804 may include edges perpendicular to the ridges corresponding to the grooves of the top 816 and bottom 812, such as Figure 8C 831. The top view of the box 800 is shown. Generally, the mutually perpendicular edges can cooperate with each other in an interlocking connection, as shown by the connections 853, 854 and 855 in the figure. Generally, to assemble the box 800, for example, the side panel 804 can be inserted into the groove 834, and then the side panel 803 is inserted into the groove 833, the side panel 802 is inserted into the groove 832, and then the side panel 801 is inserted into the groove 831. The side panels 801 and 802 can include a non-interlocking connection, as shown by the abutting edges 851 and 852 in the figure, so that the side panel 801 can be inserted without interference from the protrusion. As shown in FIG. Fig.8D The top 816 shown may include grooves 833a, 833b, 833c and 833d that may correspond to the ridges 842a, 842b, 842c and 842d of the side panels, respectively, and then arranged so that the corresponding ridges fit into the grooves of the top 816 to close the box 800. The top 816 can also be placed, for example, before all the side panels are placed, such as Fig. 8E Side panels (such as Fig. 8E The side panel 801 shown in FIG. 8 may also include a handle member, such as a handle recess 801d, to make it easier to operate the side panel.

[0296] Such embodiments of the box are described in detail in US Patent Application Nos. 13 / 549,472 and 14 / 158,488, entitled "Cargo Container for Storing and Transporting Cargo," all of which are hereby incorporated by reference in their entirety.

[0297] In a further exemplary embodiment, the box includes two identical halves 380 having a generally L-shaped cross-section, each having at least two walls and a bottom or top component, each having corresponding or complementary interlocking members to fit together to enclose the box having an enclosure, such as Fig.10 As shown. In other embodiments, the bottom may not have a recess. Each half has an inner surface and an outer surface connected by a width. The footprint of the box after disassembly or folding is no larger than the half of a roughly C-shaped cross-section mounted on the load-bearing structure of the present invention. In one embodiment, each half is made of an inner lightweight core covered with at least one layer of reinforcing coating. In another embodiment, a structured metal mesh may be inserted into the core to resist puncture of the surface. On the one hand, the box may have thermal insulation properties to minimize exposure of the cargo to low temperatures. On the other hand, the box may also have thermal insulation properties to minimize exposure of the cargo to high temperatures. In yet another aspect, the box may have a combination of the properties described in any of the preceding aspects. According to one embodiment, the box may include an outer shell having an undivided inner cavity. According to another embodiment, the box may include an outer shell having more than one internal compartment. These embodiments are also disclosed in U.S. patent application Ser. Nos. 13 / 549,472 and 14 / 158,488, both entitled “Cargo Box for Storing and Transporting Cargo,” and 13 / 254,127, entitled “Temperature-Controlled Cargo Box for Storing, Transporting and Preserving Cargo,” the contents of which are incorporated herein by reference in their entirety.

[0298] According to one embodiment, the tank may include a housing having an undivided interior cavity, such as Figure 8C According to another embodiment, the box may include an outer shell having more than one interior compartment, not specifically shown. In one aspect, the interior may have dividers molded into the sides of the component structure, (not specifically shown). In another aspect, dividers may be added to the box to form separate compartments.

[0299] The box may be sized and shaped to accommodate the cargo, or the cargo may be contained within its own packaging and then inserted into the box.

[0300] In some embodiments, the box with the outer shell can also be made of a removable or foldable box 200 for storage and / or transportation, such as Fig.16As shown, it has a bottom, four walls extending from the bottom and a top plate to enclose a shell, and the four walls are substantially similar in shape and provided with the same interlocking members, so that the box 200 can have at least three different parts: a top plate, a bottom and a wall plate. The same interlocking members on the wall plates can also generally help to form a rigid, resilient and easy to assemble / disassemble box 200.

[0301] Fig.16 A perspective view of a box 200 is shown, which may include a top plate 210, four wall plates 220 and a bottom 230, each of which or only the bottom may be a load-bearing structure of the present invention. The wall plates 220 may generally be connected to each other at a side interface 204 to form a generally rectangular box having a shape such as Fig.16a As shown in the enclosure of the space 201 , the wall panel 220 may then be joined to the bottom panel 230 at the bottom interface 206 and to the top panel 210 at the top interface 202 .

[0302] Usually, if Fig.17 and 17a As shown, the bottom 230 may include a main platform 232 on which cargo and / or other materials may rest when the box 200 is assembled. As described above, when assembled, the main platform portions of all components define the interior space of the box 200. The bottom 230 may also generally include a plurality of support members, such as legs 238 that may extend from the bottom surface 231, such as Fig.17a At the bottom interface 206 with the wall panel 220, the bottom 230 may generally include an interface feature, such as a circumferential groove 236 between the main platform 232 and the peripheral ring or edge portion 234, such as Fig.17 As shown. Typically, a portion of the wall panel 220 can be connected to the bottom 230 by being inserted into the annular groove 236. A portion of the wall panel 220 can also rest on the top surface 235 of the circumferential ring 234, so that, for example, the wall panel 220 and the bottom 230 are connected at the bottom interface 206 with a minimum gap or space. The bottom 230 can also be provided with fillets, chamfers and / or other smooth edges to minimize the pointed and / or protruding parts of the box 200, such as the chamfered edge 237 and fillet 239 of the circumferential ring 234, and the fillet 233 of the main platform 232, as shown. Fig.17 shown.

[0303] like Fig.19 and 19a As shown, the top plate 210 may generally include a main platform portion 212 and an outer surface 211, and when the box 200 is assembled, the main platform portion 212 may form a top cover. At the top interface 202 with the wall panel 220, the top plate 210 may generally include a seam member, such as a circumferential groove 216 between the inner main platform portion 212 and the outer peripheral ring 214, such as Fig.19aTypically, a portion of the wall panel 220 can be connected to the top panel 210 by being inserted into the circumferential groove 216. A portion of the wall panel 220 can also rest on the bottom surface 215 of the circumferential ring 214, so that, for example, the wall panel 220 and the top panel 210 can be connected with a minimum gap or space at the bottom surface 202. The top panel 210 can also be provided with rounded corners, chamfered corners and / or other shaped edges to minimize the protrusions and / or protrusions of the box 200, such as the chamfered edge 217 and the rounded corner 219 of the circumferential ring 234, and the rounded corner 213 of the main platform portion 212, as shown. Fig.19 and 19a shown.

[0304] Each wall panel 220 may generally include four rectangular panels 222 having seam members at their edges. In some embodiments, three of the four edges may form a stepped edge having a portion of the total thickness of the rectangular panel 222 extending outwardly to form a partial circumferential step, such as Fig.18 and 18e The step edges 226a, 226b, and 226c shown form the step 226. The fourth edge can be formed to extend in a winding manner, such as Fig.18 and 18a The extension 224 shown has a portion of the total thickness of the rectangular plate 222, which extends from the edge 223 and is wrapped around the inner surface 228 of the rectangular plate 222 at an angle of approximately 90° relative to the plane of the rectangular plate 222, which can generally form a channel or groove between the wrapped portion of the extension 224 and the unextended edge 223a of the rectangular plate 222, as shown in FIG. Fig.18 and 18a The groove 225 shown in FIG.

[0305] The stepped edges 226a, 226b, and 226c are generally shaped to fit into grooves of other components of the box 200, such as edge 226a fitting into the grooves of other components of the box 200. Fig.18b In the circumferential groove 216 of the top plate 210 shown in FIG. 1 , the edge 226 b fits into Fig.18c In the groove 225 of the other wall plate 220 shown in FIG. 1 , the edge 226c is fitted into Fig.18d 230, which can generally form a substantially continuous seam with minimal spacing and / or gaps between the components at the top interface 202, the side interface 204, and the bottom interface 206. The interface grooves, extensions, and / or corner interfaces can also generally function as tongue and groove seams, and can therefore provide a rigid and / or largely self-supporting connection between the components, which may require minimal reinforcement when assembled. These seams can also generally resist loads in all directions.

[0306] In other embodiments, Fig.18 and 18aAs shown, the wall panel 220 may also include an outer panel 222 that is connected and / or formed as a single component with an inner panel 226. One side of the outer panel 222, such as at a corner interface 234, may generally include a seam member that may generally extend beyond the edge of the inner panel 226, as shown. In some embodiments, the corner interface 234 may generally include a generally L-shaped cross-section so that it can substantially span a 90° angle to connect with another wall panel 220. The L-shaped cross-section of the corner interface 234 may generally form a groove 225 between the corner interface 234 and the inner panel 226.

[0307] The inner panel 226 may generally include an interface extending beyond the edge of the outer panel 222 (except on the edge with the corner interface 234), such as having extensions 226a, 226b and 226c, as shown. The extensions 226a, 226b and 226c may generally be shaped to fit into slots of other components of the box 200, such as the extension 226a fitting into the slots of the outer panel 222. Fig.18b In the circumferential groove 216 of the top plate 210 shown in FIG. Fig.18c The extension 226c is fitted into the groove 225 of the other wall plate 220 shown in FIG. Fig.18d 236 of the bottom 230 shown in the figure, which can generally form a substantially continuous seam with minimal spacing and / or gaps between the components at the top interface 202, the side interface 204 and the bottom interface 206. The boundary grooves, extensions and / or corner interfaces can also generally function as tongue and groove seams, and can therefore provide a rigid and / or largely self-supporting connection between the components, which may require minimal if any reinforcement when assembled. These seams can also generally resist loads in all directions.

[0308] In some embodiments, the wall panels 220 may be identical and may form a box having a square cross-section. It may be desirable for the total number of different components required to be three (top panel, bottom panel, and wall panels). In other embodiments, different sized wall panels 220 may be used, for example, with two wall panels of one length and two wall panels of another length to make the box cross-section rectangular. In general, the size of the top panel 210 and the bottom panel 230 may determine the type of wall panels 220 required to be used.

[0309] Typically, the box 200 can be assembled by connecting the wall panels 220 to the bottom 230 and covering it with the top panel 210, such as Fig. 20 Since all of the corner interfaces 224 and the extensions 226a, 226b and 226c protrude from one plane, the wall panels 220 can be inserted into the base 230 one at a time by, for example, an assembler, and the wall panels 220 can be connected to each other and to the base 230 by pure vertical translation, as shown. Fig. 20As shown, this may be suitable for reducing awkward and / or difficult assembly steps.

[0310] The bottom of the box may typically include a number of supports, such as feet, which may take different forms or shapes, e.g. Fig.21 , 21a , 21b, 21c, 21d, 21e shown in the bottom 900, 910, 920 and 930 of the support. Generally, the support member can separate the bottom surface of the bottom from the ground and / or other surface. The support members can also be spaced apart from each other, for example, a forklift and / or other moving machinery can be used to manipulate the bottom to fit into the space between the support members.

[0311] Fig.21 and 21a A plurality of legs 904 are shown extending from the bottom surface 902 of the base 900. In some embodiments, the legs may have angled walls and may have outer walls substantially perpendicular to the bottom surface 902 at the periphery of the base, as shown for the legs 904.

[0312] In some other embodiments, the legs may have angled walls and be spaced inwardly from the bottom outer edge, as shown in Figure 21b , 21c , 21d and 21e, and the feet 914, 924 and 934 of the bottoms 910, 920 and 930.

[0313] In addition, the load bearing structures of the present invention may also include ridges, ribs, reinforcements and / or other surface modifications, such as Figure 21b , 21c and 21d, for example, help further improve the structural strength and / or stiffness of the polymer core, especially the structural strength and / or stiffness under load. It is also believed that if each side wall includes a plurality of ribs, grooves or other thickness variations extending generally longitudinally, the ability of the support member and / or core to resist compressive loads will be greatly improved. Figure 21b and 21d An example of interconnected ridges or ribs 913 on the wall and bottom surface 912 of the foot 914 is shown. Fig.21c An example of a groove 923 on the bottom surface 922 is shown, with the foot 924 having unconnected ridges or ribs thereon. Fig.21e An example of a larger raised rib 933 on the bottom surface 932 is shown, with feet 934 extending from the raised rib 933.

[0314] The cargo box may also include a desiccant to control the humidity within the compartment.

[0315] In another exemplary embodiment of the present invention, the box 200 is constructed of two halves, and each half may or may not include a top or bottom component. The interlocking features on the components may include any one or all of the above-mentioned combinations. In one embodiment, the box 200 includes two identical or mirrored substantially L-shaped cross-sectional halves, such as Fig. 22 and 22a Each half has at least two wall members 220, each having corresponding interlocking members to fit together to form a box having a closed housing when mated with a top 210 and a bottom 230, such as Figure 22b shown.

[0316] In another embodiment of the present invention, the box 200 includes two identical or mirrored substantially L-shaped cross-sectional halves, such as Fig.23 and 23a The halves 210' and 230' shown in each half have at least two wall parts 220 and a top part 210 or a bottom part 230 connected to the half respectively, each part having corresponding interlocking members to fit together to form a box having, for example, a closed shell.

[0317] A box consisting of two identical, generally L-shaped cross-section halves 220' or walls, each half 220' can be integrally formed or formed by the connection of two wall portions 220, as discussed above, to connect with the top 210 and bottom 230 components. The walls can generally have the same or similar shapes and sizes, and although integrally formed or connected together, each wall portion still maintains its own platform portion 228. The half 220' can also include all components that make up the wall portion 220. As mentioned above, if the half 220' is integrally formed, the two components that normally connect the wall portions 220 may not exist, but instead form a reliable continuous structure. In these embodiments, each half 220' includes two vertical edges, such as interface surfaces 224 and 226b; and two horizontal edges, such as 226a and 226c, to interconnect with other components, such as to be connected to each other; and to connect with the top 210 and the bottom 230 to form a box 200 having an interior space 201, such as Figure 22b The halves 220' can nest together, for example due to their shape and identical conformation, which generally saves space during storage in the disassembled form.

[0318] In one embodiment, one generally L-shaped cross-section half may be integrally formed or connected to the top member, such as Fig.23a The half 210' formed by connecting the wall 220 to the top 210 is shown in FIG. The other half of the generally L-shaped cross section can be integrally formed or connected to the bottom or bottom part, such as Fig.23As shown, the half 230' is formed by connecting the wall 220 to the bottom 230, so that the two halves 210', 230' can be assembled to form a complete closed box 200, such as Figure 23b As shown in FIG. 2 , the wall portions in the half portions 210 ′ and 230 ′ may generally have the same or similar shapes and sizes as the half portions 220 ′, and although integrally formed or connected together, each wall portion still maintains its respective platform portion 228 . The half portions 210 ′ and 230 ′ may also include all components constituting the wall portion 220 . Similarly, if the half portions 210 ′ and 230 ′ are integrally formed, the components constituting the normal contact between the two wall portions 220 and the top portion 210 or the bottom portion 230 may not exist, and a reliable continuous structure may be formed. In these embodiments, each half 210', 230' includes two vertical edges, such as edges 224 and 226b, and two horizontal edges, such as 226a and 226c, to interconnect with other components, such as to connect with each other, and the bottom 230 may include a groove 236 to contact the edge of the half 230', and the top 210 may include a groove 216 to contact the edge of the half 230' to form a box 200 with an interior space 201, such as Figure 23b The halves 210', 230' can nest together, for example due to their shape and proximity, which generally saves space during storage in a disassembled form.

[0319] For the above-mentioned half parts 210', 220', 230', the edges can be rounded or chamfered, such as the rounded edge 223 shown in the figure, or can be non-circular or smooth substantially 90-degree interface (not shown in the figure).

[0320] As described above, the seam member can be formed at any step in the manufacturing process. In one example, the member can be molded when each component is made. The bottom, top or wall may include a lightweight core, such as a closed-cell foam core, combined with a polymer film or surrounded by a polymer film to form a reinforcement structure. The core may include a seam member, and the polymer film may match the member of the core in the combination or surrounding step or process. In another embodiment, the member can be forged into the component after the component is made, for example, the bottom, top or wall may include a lightweight core (such as a closed-cell foam core) combined with a polymer film or surrounded by a polymer film to form a reinforcement structure. The core does not include any seam members. The seam member can be forged after the core and the film are combined, and the exposed surface of the core can remain exposed or increase spraying to cover the exposed surface of the core.

[0321] In various embodiments of the platform of one or more pads of the present invention, the first shell and the second shell are made of a core, made of one or more materials, including expanded polystyrene, polyurethane, polyphenylene oxide, pentane impregnated polystyrene, a mixture of polyphenylene oxide and pentane impregnated polystyrene, polyethylene, polypropylene, etc. In various embodiments of the platform of one or more pads of the present invention, the first shell and the second shell are made of a core comprising one or more of the above materials. In various embodiments of the platform of one or more pads of the present invention, the first shell and the second shell are made of one or more thermoplastic sheets or layers, and the thermoplastic sheets or layers include high-impact polystyrene, such as polyolefins of polypropylene, low-density polyethylene, high-density polyethylene, polyethylene and polypropylene; polycarbonate; acrylonitrile-butadiene-styrene; polyacrylonitrile; polyphenylene oxide; polyphenylene oxide alloys with high-impact polystyrene; polyesters such as PET (polyethylene terephthalate), APET and PETG; lead-free polyvinyl chloride; copolyester / polycarbonate; or a composite HIPS structure as described above.

[0322] In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell thermoplastic sheets are formed from a mixture of any of the above-mentioned polymers. In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell are formed from a core with embedded reinforcement material, the reinforcement material is selected from the group consisting of wire mesh, punched sheet, and the barrier is embedded in the core. In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell are formed from a core with embedded reinforcement material, the reinforcement material is selected from the group consisting of metal, carbon fiber, aramid, basalt-web blanket and bakelite. As described above, non-metallic boxes can be used when used to facilitate security inspection of air cargo of cargo that is transparent to magnetic scanners.

[0323] As described above, the polymer layer (e.g., a sheet or coating on the polymer layer) may include a chemical antimicrobial substance or compound that is capable of being essentially permanently, at least for a period of time such as the life of the load-bearing structure or when coated with a processing aid or coating agent, bonded to the exposed surface of the polymer layer (e.g., sheet or coating 67). In one example, the chemical can be placed on the surface of the polymer layer (e.g., sheet or coating 67) or incorporated into the material of the polymer layer (e.g., sheet or coating 67). The surface 16 can have its own inherent antimicrobial activity, for example, by covalently bonding the antimicrobial agent to the surface of the polymer layer (e.g., sheet or coating 67), or if incorporated into the bulk material used to make the polymer layer (e.g., sheet or spray coating), it may migrate to the surface. These covalently bonded materials can minimize microbial growth on the surface, whether it is disposable or reusable. In addition, any microbial organisms that may have the opportunity to attach to the material can be killed by interaction with the coating. For example, quaternary ammonium cations (e.g., N-alkyl-pyridinium) can be used as antimicrobial moieties in covalently attached polymer surface coatings. In one instance, the aforementioned poly(4-vinyl-N-hexylpyridine) (N-alkyl-PVP) was previously known to have an optimal alkyl side chain length for antimicrobial activity. Polyethyleneimine (PEI) has also previously been used as an antimicrobial coating when N-alkylated on its primary amino groups and subsequently N-methylated on its secondary and tertiary amino groups to increase the total number of quaternary ammonium cationic groups. Any such covalently bonded quaternary ammonium cationic polymer coating can be used to provide antimicrobial properties to one or more surfaces of a load-bearing structure. Other examples of quaternary ammonium compounds include, but are not limited to, benzalkonium chloride, benzethonium chloride, methylbenzylmethionium chloride, cethacrylonium chloride, cetylpyridinium chloride, cetrimonium, cetrimide, dofanium chloride, ammonium, tetraethylammonium bromide, didecyldimethylammonium chloride, and domiphene bromide.

[0324] For incorporating one or more antimicrobial agents into the material used to make the polymer layer (e.g., sheet or spray coating), one or more formulations can be dispersed into the material directly or dispersed into the material with the help of a suitable carrier (e.g., adhesive, solvent, or suitable polymer mixing aid). These carriers can be selected so that they can be mixed with the material used to make the polymer layer (e.g., sheet or spray coating) and are compatible with the one or more antimicrobial agents used. Effective adhesives are those that do not interfere with the antimicrobial activity of the antimicrobial agent.

[0325] As noted above, additional enclosures, such as bag-like enclosures, may be used to cover any of the above-described load-bearing structures. The present invention also discloses a system intended to facilitate security inspection procedures, including a lightweight load-bearing structure for loading perishable or non-perishable cargo, the load-bearing structure having a top deck, a bottom deck, and a width connecting the top and bottom, the bottom deck having a plurality of legs extending therefrom and cargo loaded onto the top deck of the load-bearing structure; and a bag-like enclosure for covering the cargo and at least a portion of the width of the load-bearing structure, the bag-like enclosure having an opening resilient around its periphery for stretching to approximately the width of the load-bearing structure. The load-bearing structure and the bag-like enclosure of such a structure are both transparent relative to the magnetic imaging scanner used in security scanning to facilitate security inspections of perishable or non-perishable cargo, large or small cargo, without requiring unloading and reloading of cargo from the load-bearing structure.

[0326] The bag-like shell can be made of film, fabric sheet or non-woven sheet, and these materials have enough strength for stretching and covering goods, and are light enough to not add unnecessary weight to goods. Can be closed on three sides and open at one end, and the opening of the open end has some elasticity around. Goods can be packaged and the bag-like material is stretched on the whole goods, the open end stretches under the edge of the bottom and labels at the starting point, and the whole structure can be packaged by shrink film. The surface of the bag-like material can also have antibacterial properties. Any of the above-mentioned antibacterial embodiments may be suitable. More details are found in application number 13 / 549477, the U.S. patent application entitled "System for Promoting Shipment Safety Inspection", and its content is incorporated by reference in its entirety at this.

[0327] Example 1: Load testing of a pad platform without long members

[0328] According to ASTM D1185-2009 Figure 6 A multi-day load test was conducted on a sample of a pad platform in the form of a polymer core 10, wherein the polymer core 10 is supported by a guide rail 80 under the supports 20, 21, 22 and a guide rail 80 under the supports 26, 27, 28, the guide rails being centrally located 75 mm from the edge, as in Fig.29 and Fig.29a The support members 23, 24, 25 are not supported by the guide rails 80, which represents a more severe load situation than in actual situations. The sample polymer core 10 has dimensions of 120×100×13.9 cm and a mass of 3.5 kg. The 750 kg sample load mass of the example box is substantially evenly distributed on the surface of the polymer core 10, as shown in FIG. Fig.29 , 29a As shown, when cargo 490 is fastened to the polymer core 10, the load stress is measured by measuring the vertical deflection F relative to the original plane for eight days, as shown in FIG. Fig.29 , 29aThe deflection was measured once a day for eight days. At the conclusion of the test no damage or cracking was observed and the following deflections were measured:

[0329] Table 1: Maximum deflection measured at unsupported supports (mm)

[0330] Number of days Support 25 Support 24 Support 23 0 0 0 0 1 5.8 7.87 9.24 2 7.72 10.02 10.53 3 9.16 12.53 12.91 4 10.03 13.47 13.75 5 10.87 14.3 14.95 6 11.5 14.91 15.08 7 11.73 15.31 15.43 8 12.42 15.89 15.79

[0331] The maximum deflection measured after 192 hours was 15.89 mm.

[0332] Example 2: Load testing of a pad platform with long members

[0333] For Figure 6i A sample of a backing plate platform in the form of a polymer core (the backing plate platform is made of Figure 3 and 3a The long recess 15-1 of the insert member 17 shown is subjected to a multi-day load test according to ASTM D1185-2009, and the polymer core 10 is supported by a guide rail 80 located below the supports 20, 21, 22 and a guide rail 80 located below the supports 26, 27, 28, and the guide rail is centrally located 75mm from the edge, as shown in FIG. Fig.29 and 29a The support members 23, 24, 25 are not supported by the guide rails 80. The sample polymer core 10 has dimensions of 120 x 100 x 13 cm and a mass of 5.4 kg. The 900 kg sample load mass of the example box is distributed approximately evenly over the surface of the polymer core 10, as shown. Fig.29 , 29a As shown, when cargo 490 is fastened to the polymer core 10, the load stress is measured by measuring the vertical deflection F relative to the original plane for eight days, as shown in FIG. Fig.29 , 29a At the conclusion of the test no damage or cracking was observed and the following deflections were measured:

[0334] Table 2: Maximum deflection measured at unsupported supports (mm)

[0335] Hour Support 25 Support 24 Support 23 10 0 0 0 24 2.24 2.19 1.72 396 4.57 4.15 3.76 4192 6.25 5.84 4.75

[0336] The maximum deflection measured after 192 hours was 6.25 mm. Compared to Sample 1 employed in Example 1, this polymer core 10 having the member 17 inserted into the recess 15 - 1 , although thinner, had a greatly reduced deflection at higher loads.

[0337] Example 3: Load testing of a pad platform with long members

[0338] For Figure 6iA sample of a backing plate platform in the form of a polymer core (the backing plate platform is made of Figure 3 and 3a The long recess 15-1 of the insert member 17 shown is subjected to a multi-day load test according to ASTM D1185-2009, and the polymer core 10 is supported by a guide rail 80 located below the supports 20, 21, 22 and a guide rail 80 located below the supports 26, 27, 28, and the guide rail is centrally located 75mm from the edge, as shown in FIG. Fig.29 and 29a The support members 23, 24, 25 are not supported by the guide rails 80, which represents a more severe load situation than in actual conditions. The sample polymer core 10 has dimensions of 120×100×12 cm and a mass of 2.76 kg. The 660 kg sample load mass of the example box is roughly evenly distributed on the surface of the polymer core 10, as shown. Fig.29 , 29a As shown, when cargo 490 is fastened to polymer core 10, load stress is measured by measuring the vertical deflection F relative to the original plane for fourteen days, as shown in FIG. Fig.29 , 29a At the conclusion of the test no damage or cracking was observed and the following deflections were measured:

[0339] Table 3: Maximum deflection measured at unsupported supports (mm)

[0340] Hour Support 25 Support 24 Support 23 10 1.400 01.14 01.47 24 32.234 23.1996 13.728 3168 64.257 47.1584 38.7691 4336 76.725 510.684 413.7517

[0341] The maximum deflection measured after 336 hours was 13.17 mm. Compared to the sample employed in Example 1, the polymer core 10 having the member 17 inserted into the recess 15-1, despite being thinner and lighter overall, has less deflection over a significantly longer time span.

[0342] While the invention has been particularly shown and described with reference to exemplary embodiments, it will be understood by those skilled in the art that changes in form and details may be made without departing from the spirit and scope of the invention.

Claims

1. A bearing structure, comprising: a polymer core having a top side, a bottom side, and a width portion, the width portion having a thickness connecting the top side and the bottom side, the bottom side including at least one depression extending substantially along a length or width of the bottom side, the at least one depression including one depression, a group of closely spaced depressions, or a combination of one depression and a group of closely spaced depressions; at least one corresponding member cooperating with one of the at least one recess, the corresponding member comprising at least one raised portion and two flat side portions extending from both sides of the raised portion, the flat side portions and the raised portion being integrally formed; and at least one polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being bonded to at least a portion of the top side, the bottom side, and the width portion of the polymer core; Wherein, the polymer core includes an outer edge, and a portion of the outer edge includes a roughened portion.

2. The bearing structure according to claim 1, wherein: The raised portion of the at least one respective member comprises a substantially dome-shaped cross-section, a substantially rectangular cross-section, a substantially trapezoidal cross-section, or a substantially triangular cross-section.

3. The bearing structure according to claim 1 or 2, wherein: The at least one respective member includes a partially hollow interior or a substantially hollow interior.

4. The load-bearing structure according to claim 1, wherein: The roughened portion includes sawtooth-shaped features.

5. The bearing structure according to claim 1 or 2, wherein: The mating of the recess with the corresponding member occurs before or after the polymer core is bonded to the polymer sheet.

6. The load-bearing structure according to claim 1 or 2, wherein: The at least one recess comprises a single recess or a group of closely spaced recesses, and not all recesses cooperate with corresponding members.

7. The bearing structure according to claim 1 or 2, wherein: The outer edge of the first side of the polymer sheet is sealed together with portions of the polymer core by at least one sealing member.

8. The load-bearing structure according to claim 1 or 2, wherein: The entire flat side is of uniform thickness, or the flat side tapers toward the end.

9. The load-bearing structure according to claim 1 or 2, wherein: The at least one recess extends in one or more directions along at least a portion of the bottom side.

10. The load-bearing structure according to claim 1 or 2, wherein: Also included is at least one edge protector located adjacent a portion of the bottom side and a portion of the width portion of the bottom side proximate the load-bearing structure for receiving at least one cargo retaining member.

11. The load bearing structure of claim 1 or 2, further comprising a plurality of supports extending orthogonally from a bottom side of the polymer core, each of the plurality of supports comprising a solid interior or a partially hollow interior.

12. The load-bearing structure according to claim 11, wherein: Each of the partially hollow interiors forms one or more depressions on the bottom surface of the support member for mating with a corresponding component so as to have a substantially flat feel or appearance that, when mated, substantially conceals any indication that it is hollow.

13. A load-bearing structure having a top side, a bottom side, and a width portion between the top side and the bottom side, the load-bearing structure comprising: A foamed polymer core having a top side, a bottom side, and a width portion, the width portion of the foamed polymer core having a thickness connecting the top side of the foamed polymer core and the bottom side of the foamed polymer core, the foamed polymer core having an outer edge, the bottom side comprising: a plurality of supports extending orthogonally from the bottom side of the core; at least one recess extending between adjacent supports; and at least one recess extending substantially along the length or width of the bottom side, the at least one recess extending substantially along the length or width of the bottom side comprising a single recess or a group of closely spaced recesses; a corresponding member cooperating with the at least one recess, the corresponding member having a raised portion integrally formed with two flat side portions; a first polymer sheet having a first side and a second side with an outer edge, the first side and its outer edge being respectively bonded to at least a portion of the thickness of the width portion of the foamed polymer core, the bottom side, and the plurality of supports; and a second polymer sheet having a first side with an outer edge portion and a second side, the second side of the second polymer sheet and the outer edge portion thereof being bonded to the foamed polymer core over at least a portion of the thickness of the width portion and the top side of the foamed polymer core, respectively, thereby forming an overlap between the outer edge portion of the first polymer sheet and the outer edge portion of the second polymer sheet around the width portion; wherein the outer edge of the foamed polymer core includes an outer edge having at least a portion of a roughened outer edge.

14. The load-bearing structure according to claim 13, wherein: Each support of the plurality of supports comprises at least one recess on a side facing an adjacent support, the recess being an extension of and adjacent to a recess on the bottom side of the polymer core.

15. The load-bearing structure according to claim 13 or 14, further comprising a top part arranged on top of the load-bearing structure to form a closed box.

16. The load-bearing structure according to claim 13 or 14, wherein: At least a portion of a bottom of each of the plurality of support members includes a recess.

17. The load bearing structure of claim 13 further comprising at least one edge protector surrounding a bottom edge of the bottom side and a portion of the width portion proximate the bottom edge of the load bearing structure for receiving at least one cargo retaining member.

18. The load-bearing structure of claim 15, further comprising a recess on one side of the load-bearing structure for arranging a phase change material.

19. The load-bearing structure according to claim 16, wherein: The recess of the support member cooperates with a corresponding component.

20. The load bearing structure of claim 13, 14, 17 or 19, further comprising at least one bridge member spanning between adjacent support members.

21. The load-bearing structure of claim 13, 14, 17 or 19, wherein: The at least one recess extending between adjacent supports extends in one or more directions.

22. The load-bearing structure according to claim 13 or 14, wherein: Each support member of the plurality of supports includes a solid interior or a partially hollow interior.

23. The load-bearing structure according to claim 22, wherein: Each of the partially hollow interiors forms one or more depressions on the bottom surface of the support member for mating with a corresponding component so as to have a substantially flat feel or appearance that, when mated, substantially conceals any indication that it is hollow.

24. A load-bearing structure for loading, transporting or storing goods, the load-bearing structure comprising: a foamed polymer core having a top side, a bottom side, and a width portion having a thickness connecting the top side and the bottom side, and a plurality of supports extending orthogonally from the bottom side of the core, each of the plurality of supports including a solid interior or a partially hollow interior; at least two substantially parallel spaced apart recesses extending substantially along the length or width of the bottom side of the core, the longer of the recesses cooperating with respective members; a first polymer sheet having a first side with an outer edge and a second side, the first side of the first polymer sheet including the outer edge being bonded to at least a portion of the width portion of the foamed polymer core, the bottom side, and the plurality of supports; as well as a second polymer sheet having a first side with an outer edge and a second side, the second side and its outer edge being bonded to the foamed polymer core over at least a portion of the width portion and the top side of the foamed polymer core, wherein the outer edge of the first polymer sheet overlaps the outer edge of the second polymer sheet around the width portion; Wherein, the polymer core includes an outer edge having at least a portion of the outer edge having a serrated edge.

25. The load bearing structure of claim 13, 14, 17 or 19, wherein: The polymer core has a thickness of between 120 mm and 130 mm.

26. The load-bearing structure according to claim 24, wherein: Each of the recesses spans 75% of the width or length of the core.

27. The load bearing structure of claim 24, further comprising depressions on the bottom side between the supports, the depressions cooperating with corresponding members.

28. The load-bearing structure according to claim 24, wherein: Each of the partially hollow interiors forms one or more depressions on the bottom surface of the support member for mating with a corresponding component so as to have a substantially flat feel or appearance that, when mated, substantially conceals any indication that it is hollow.

29. The load bearing structure of claim 13, 14, 17 or 19, wherein: The load bearing structure supports at least fifteen times its own weight for one week with an average deflection of less than 2%.

30. A bearing structure, comprising: a polymeric core having a top side with outer edges, a bottom side with outer edges, and a width portion having a thickness connecting the top side and the bottom side, at least a portion of at least one of the outer edges comprising a roughened edge portion; a plurality of supports extending orthogonally from the bottom side of the polymer core; and at least one polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being bonded to at least a portion of the top side of the polymer core, the bottom side, the plurality of supports, and the width portion; Wherein, the roughened edge portion is arranged on the outer edge of the polymer core, and the roughened edge includes a notch.

31. The load-bearing structure according to claim 24, wherein: Only two or no more than three of the recesses extending substantially along the length and width of the bottom side of the core and the recesses extending between the supports cooperate with corresponding components and all other remaining recesses are in the load-bearing structure.

32. A load-bearing structure for loading, transporting or storing goods, the load-bearing structure comprising: a foamed polymer core having a top side, a bottom side, and a width portion having a thickness around an edge connecting the top side and the bottom side; a first polymer sheet having a first side with an outer edge portion bonded to the foamed polymer core on the bottom side and to at least a portion of the thickness of the width portion of the foamed polymer core, respectively; a second polymer sheet having a first side with an outer edge and a second side, the second side and its outer edge being bonded to the foamed polymer core over at least a portion of the width portion and the top side of the foamed polymer core, wherein the outer edge of the first polymer sheet overlaps the outer edge of the second polymer sheet around the width portion; At least one member for reducing the overall weight of the load-bearing structure and increasing the strength of at least one of the edges of the load-bearing structure, the member comprising a roughened edge portion.

33. The load-bearing structure according to claim 30, wherein: The roughened edge portion is shaped as a sawtooth edge.

34. The load bearing structure of claim 30, further comprising at least one depression on a bottom side of the polymer core, the at least one depression extending substantially along a length or a width of the bottom side.

35. The load-bearing structure according to claim 30, wherein: The roughened edge portion of the polymer core retains its shape after being combined with the polymer sheet to form a load-bearing structure.

36. The load-bearing structure of claim 34, further comprising a corresponding member cooperating with at least one of the recesses, the corresponding member having a raised portion.

37. The load-bearing structure according to claim 36, wherein: The raised portion of the respective member includes a hollow interior.

38. The load-bearing structure according to claim 33, wherein: The teeth of the serrated edge may have a length equal to the thickness of a width portion of the edge, or may have a length equal to half the thickness of a width portion of the edge, or the length of each tooth may be any length between half the length and the full length.

39. The load-bearing structure according to claim 32, wherein: The roughened edge portions do not extend further from the sides of the foamed polymer core than the unroughened edge portions.

40. The load bearing structure according to claim 32, wherein: The roughened edge portion extends a length along the edge of the foamed polymer core and is occasionally interrupted by non-roughened edge portions.

41. The load-bearing structure according to claim 40, wherein: The roughened edge portion is present along two parallel sides of the foamed polymer core, or the roughened edge portion is present along all sides of the foamed polymer core.

42. The load-bearing structure according to claim 34, wherein: The at least one depression comprises at least one single depression or at least one group of closely spaced depressions.

43. The load-bearing structure according to claim 32, wherein: The bottom side also includes a plurality of supports extending substantially orthogonally from the bottom side of the foamed polymer core, each support of the plurality of supports having a first side surface, a bottom surface, and a second side surface.

44. The load-bearing structure according to claim 43, wherein: The support includes a hollow interior that cooperates with a second member for sealing a top portion of the hollow interior.

45. The load bearing structure of claim 32, wherein: The member comprises a series of small indentations disrupting the continuity of the edge of the load bearing structure.

46. ​​The load-bearing structure according to claim 45, wherein: The indentations are formed in the foamed polymer core during or after forming the foamed polymer core.

47. The load bearing structure of claim 36, wherein: The roughened edge portion exists continuously or intermittently along a width portion connecting the top side and the bottom side of the polymer core.

48. A load-bearing structure for loading, transporting or storing goods, the load-bearing structure comprising: a foamed polymer core having a top side with an outer edge, a bottom side with an outer edge, and a width portion having a thickness connecting the top side and the bottom side of the foamed polymer core; at least one polymer sheet having a first side with an outer edge portion bonded to the bottom side of the foamed polymer core and at least a portion of the width portion of the foamed polymer core to form a load-bearing structure having an outer edge; and at least one member disposed along a portion of at least one of the outer edges of the foamed polymer core, the member including a roughened edge portion for reducing the overall weight of the load-bearing structure and increasing strength in the outer edge of the load-bearing structure; Wherein the roughened edge portion of the foamed polymer core comprises notches.

49. The load-bearing structure according to claim 30 or 47, wherein: The roughened edge is a sawtooth edge.

50. The load bearing structure of claim 49, further comprising at least one recess on a bottom side of the polymer core, the at least one recess extending substantially the length or width of the bottom side.

51. The load bearing structure of claim 50, further comprising a corresponding member cooperating with at least one of the recesses to substantially fill the recess, the corresponding member having a raised portion.

52. The load bearing structure of claim 48, further comprising a non-roughened outer edge portion, wherein: The roughened edge portion does not extend further from the outer edge of the foamed polymer core than the unroughened edge portion.

53. A bearing structure, comprising: a polymer core having a top side with an outer edge, a bottom side with an outer edge, and a width portion having a thickness connecting the top side and the bottom side; a plurality of supports extending orthogonally from the bottom side of the polymer core, each of the supports having a bottom surface; and at least one polymer sheet having a first side with an outer edge portion, the first side of the polymer sheet including the outer edge portion being bonded to at least a portion of the top side of the polymer core, the bottom side, the plurality of supports, and the width portion; Wherein, the bearing structure includes a guide member to better position any retaining member; Wherein at least a portion of at least one of the outer edges comprises a roughened edge portion.

54. The load bearing structure of claim 53, further comprising at least one bridge member attached to the bottom surfaces of adjacent support members in a row.

55. The load-bearing structure according to claim 54, wherein: The bridge is arranged in a recessed portion of a bottom surface of each of the supports.

56. The load bearing structure of claim 53, wherein: The guide members between adjacent supports are adapted to receive at least one cargo retaining member.

57. The load bearing structure of claim 30, further comprising at least one depression on the bottom side of the polymer core.

58. The load-bearing structure of claim 57, further comprising a corresponding member cooperating with the at least one recess, the corresponding member having a raised portion.

59. The load-bearing structure according to claim 57 or 58, wherein: The at least one depression on the bottom side of the polymer core comprises a single depression or a group of closely spaced depressions.

60. The load-bearing structure according to claim 57 or 58, wherein: The at least one recess on the bottom side of the polymer core extends substantially along a length or a width of the bottom side.

61. A bearing structure, comprising: a polymer core having a top side, a bottom side, and a width portion having a thickness connecting the top side and the bottom side, the bottom side including at least one depression extending substantially along a length or width of the bottom side, the at least one depression including a single depression, a group of closely spaced depressions, or a combination of a single depression and a group of closely spaced depressions; at least one corresponding member cooperating with one of the at least one recess, the corresponding member comprising at least one raised portion and two flat side portions extending from both sides of the raised portion; and a first polymer sheet having a first side with an outer edge, the first side of the polymer sheet including the outer edge being bonded to the bottom side and the width portion of the polymer core; Wherein, the bearing structure includes a guide member to better position any retaining member; Wherein, the polymer core includes an outer edge, and a portion of the outer edge includes a roughened portion.

62. The load-bearing structure according to claim 61 further includes a second polymer sheet, the second polymer sheet having a first side with an outer edge portion and a second side, the second side and its outer edge portion being combined with the polymer core on at least a portion of the width portion and the top side of the polymer core, wherein the outer edge portion of the first polymer sheet overlaps with the outer edge portion of the second polymer sheet around the width portion.

63. The load-bearing structure according to claim 61 or 62, wherein: The guide members are present discontinuously or continuously around some of the outer edges of the polymer core.

64. The load-bearing structure according to claim 61 or 62, wherein: The guide members are present around the outer edge of the load-bearing structure to better position the retaining members.

65. The load bearing structure of claim 63, wherein: The guide member includes an indentation surrounding the bottom side and an outer edge of the width portion.

66. The load-bearing structure according to claim 61 or 62, wherein: The polymer core has a thickness between 1 cm and 5 cm.

67. The load bearing structure of claim 62, wherein: The outer edge portion of the first polymer sheet and the outer edge portion of the second polymer sheet overlap around the width portion by at least one sealing member.

68. The load bearing structure of claim 61 or 62, further comprising a plurality of supports extending orthogonally from a bottom side of the core, each of the plurality of supports comprising a bottom surface and a solid interior or a partially hollow interior.

69. The load bearing structure of claim 68, further comprising at least one bridge member spanning between adjacent support members in a row.

70. The load bearing structure of claim 67, further comprising at least one bridge member attached to the bottom surfaces of adjacent support members in a row.

71. The load bearing structure of claim 69, wherein: The at least one bridge spans the width or length of the base of the load bearing structure.

72. The load bearing structure of claim 71, wherein: The bridge is arranged in a depressed portion of a bottom surface of each of the plurality of support members.

73. The load-bearing structure according to claim 61 or 62, wherein: The at least one recess is recessed to accommodate the two flat side portions extending from both sides of the raised portion, forming a flat appearance on the bottom side of the load-bearing structure.

74. The load bearing structure of claim 68, wherein: Each of the partially hollow interiors forms one or more depressions on the bottom surface of the support member to mate with a corresponding member to have a flat feel or appearance that, when mated, substantially conceals any indication that it is hollow.

75. The load bearing structure of claim 33, wherein: The roughened edge portions do not extend further from the sides of the polymer core than the unroughened edge portions.

76. The load bearing structure of claim 33, wherein: The roughened edge portion extends a length along the edge of the polymer core and is occasionally interrupted by non-roughened edge portions.

77. The load bearing structure of claim 33, wherein: The bottom side also includes a plurality of supports extending substantially orthogonally from the bottom side of the polymer core, each support of the plurality of supports having a first side surface, a bottom surface, and a second side surface.

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