Mold set for manufacturing EPS pallet and use thereof

Abstract

To provide a set of molds for manufacturing expanded polystyrene (EPS) pallets, a method for manufacturing a set of molds for manufacturing EPS pallets, and a method for manufacturing EPS pallets using the set of molds.SOLUTION: A set of molds includes a leg mold designed to manufacture modular platform molds, EPS pallet platform sections, and multiple leg support sections. The modular platform mold has a modularized unit, and this modularized unit enables changing the dimensions of the hollow space configured to receive polystyrene bead feedstock, thereby enabling the molding of platform sections of various dimensions from a single mold. One or more leg support sections are attached to the bottom side of the platform section at predetermined locations based on load-bearing capacity and lifting position to form an EPS pallet.SELECTED DRAWING: Figure 2a

Description

Technical Field

[0001] Embodiments of the present invention relate to a method of manufacturing a set of molds for the manufacture of pallets, particularly for the production of expanded polystyrene (EPS) pallets, and to the use of a set of molds for pallet production.

[0002] 〔Cross-reference to Related Applications〕 This application claims priority from a complete patent application No. 202021036424 (Title of the Invention: A MOULD SET FOR FABRICATION OF AN EPS PALLET AND USE THEREOF) filed in India on August 24, 2020.

Background Art

[0003] A pallet is a flat transport structure that supports goods in a stable manner when lifted by a forklift, pallet jack, front loader, jacking device, or overhead crane. The pallet forms the structural basis of a unit load that enables high handling and storage efficiency. Pallets are manufactured using various materials such as wood, metal, some recycled products, plastic, expanded polystyrene (EPS), high-impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), etc. In the conventional method, the manufacture of such EPS pallets involves the design of a mold and the production of the pallet using the mold. The method of manufacturing the mold begins with the design of a pallet of standard or customized dimensions and shape. This design is based on the use of, for example, a racking pallet for heavy-duty purposes or an export pallet for one-time transportation. However, regarding standard-sized pallets, how to design them is not a problem because the design has already been done. In contrast, for the custom design of pallets, the input from the client regarding requirements needs to be accepted to match the specifications that have a significant impact on the design. Any change in the requirements will result in a change in the pallet design, and thus, the drawing needs to be redone. Furthermore, as a result of changes in specifications or design, a change in the material used for pallet formation may also be made. The design of tools for thermoformed plastics is also one of the most challenging steps in the EPS pallet forming process because any mistake at this point will have a negative impact on the EPS core, resulting in rework for the final product or the EPS pallet. As can be easily understood in light of the above, the mold should be customized according to requirements, but implementing customization will surely increase capital expenditure and time.

[0004] Furthermore, when designing the mold, the EPS pallet forming process may be initiated. EPS and HIPS / ABS pallets require two basic raw materials, namely, expanded polystyrene for making the core and impact-resistant polystyrene for making the top layer called the sheet. During molding, the EPS is placed on the machine and the sheet is heated to a flexible or moldable temperature. In this process, compressed air is injected between the two hot sheets so that the EPS conforms to the contour of each of the two molds provided facing each other. The evacuation of air between the sheets is assisted by vacuum. However, as a result of such a conventional method, the capital cost becomes high because EPS pallets require a forming machine to form the pallets. Such machines are costly. Also, a large amount of energy is consumed to operate this machine and a constant supply of a large amount of energy in the form of electricity is required. This machine also requires two different molds for operation, namely, (a) a casting mold for making the EPS core, and (b) a forming mold consisting of "top" and "bottom" for forming the pallet. All vendors need to hold a set of casting molds of all sizes for the purpose of supplying the EPS core used as one of the raw materials. This significantly increases the overhead costs. When the number of pallet orders is large, this is directly proportional to the increase in capital expenditure in terms of molds and machines.

[0005] In addition, such machines require a large amount of space. Storing casting molds in different sizes and orientations creates such accessibility difficulties. This also requires skilled manpower with expertise in operating the equipment to ensure the desired output of the product. In addition, the machine also requires certain maintenance costs and backup support. Considering that the machines are mostly imported, the backup support may not be prompt. Also, the thin-walled EPS pallets made by vacuum forming have limited impact strength, thereby creating structural limitations over the conventional method.

[0006] A new method is disclosed in U.S. Patent No. 6418861 (B1) compared to the conventional method, and such a new method attempts to solve the problems of the conventional method. This U.S. Patent discloses a method for forming a modular pallet, where one pallet is composed of combining a number of plates, and such a pallet has tabs and grooves that assist in the combination of a number of plates for forming a deck. To keep the plates intact, the pallet is joined using a number of beams and rods. However, due to the additional components used to join the number of plates, the required materials needed for such a new method are increasing. Also, this method is less convenient for heavy-duty purposes, because the pallet is weak due to a number of bolts and connections, and therefore, such a pallet tends to break easily. Due to such drawbacks, pallets of this new method are limited to use by forklifts, pallet jacks, front loaders or any other machinery.

Prior Art Documents

Patent Documents

[0007]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0008] Therefore, an improved set of molds for manufacturing pallets and a manufacturing method thereof are desired to address the above problems.

Means for Solving the Problems

[0009] According to an embodiment of the present invention, a set of molds for manufacturing an EPS pallet is disclosed. The set of molds includes a modular platform mold (70) configured to act as a mold for the platform section of the EPS pallet. The modular platform mold has a bottom plate (80) of a predetermined dimension and a top plate (100) of a predetermined dimension. The top plate is configured to fit on top of the bottom plate (80) with a hollow space (90) corresponding to the dimensions of the platform section of the EPS pallet formed between the top plate (100) and the bottom plate (80). The hollow space (90) is configured to receive a polystyrene bead supply. The set of molds further has a modular unit configured to change the dimensions of the hollow space. The modular unit includes a first elongated panel (110a) having a plurality of first segments (120a). The first elongated panel (110a) is longitudinally oriented on a first side of the bottom plate (80) and is housed within the hollow space (90). Each of the plurality of first segments is operable independently laterally to move from a first position to a second position, thereby configuring the length of the hollow space (90) to be changed. The modular unit further includes a second elongated panel (110b) having one or more second segments (120b). The second elongated panel (110b) is laterally oriented on a second side of the bottom plate (80) while being housed within the hollow space (90). Each of the one or more second segments (120b) is operable independently laterally to move from a first position to a second position, thereby configuring the width of the hollow space (90) to be changed.

[0010] According to another embodiment of the present invention, a set of molds for manufacturing an EPS pallet further includes a leg mold (70) configured to act as a mold for manufacturing a plurality of leg support sections corresponding to the platform section of the EPS pallet. The leg mold has a bottom layer (150) provided with a plurality of inlets for at least one of air, water, and steam, one or more outlets, and one or more openings for receiving a polystyrene bead supply. The leg mold has an intermediate layer (160) provided with a plurality of cavities of a predetermined dimension, and the bottom side of the intermediate layer (160) is configured to cover the top side of the bottom layer (150). The leg mold has a top layer (190) provided with a plurality of inlets and one or more outlets for at least one of air, water, and steam, and the top layer is configured to fit over the top side of the intermediate layer in a state of sealing the plurality of hollow cavities of the intermediate layer. The plurality of sealed hollow cavities are configured to receive a polystyrene bead supply through one or more openings of the bottom layer (150) to shape a plurality of leg support sections.

[0011] According to still another embodiment of the present invention, a method for manufacturing a set of molds for manufacturing an EPS pallet is disclosed. The method includes the step of drawing a plurality of patterns for the base of one of a modular platform mold (70) and a leg mold (200), the patterns including a plurality of rib locations, a plurality of supply locations, and steam jet intervals. The method further includes the step of separately manufacturing each of the plurality of patterns independently using one of wood or expanded polystyrene (EPS). The method includes the step of casting each of the plurality of manufactured patterns. The method further includes the step of polishing the plurality of cast patterns using a buffing method. The method further includes the step of combining one or more of the cast patterns of the plurality of polished patterns to obtain one of the modular platform mold (70) and the leg mold (200).

[0012] According to an embodiment of the present invention, a method for manufacturing an EPS pallet is disclosed. The method includes the step of mixing polystyrene beads with at least one type of antifungal component and a flame retardant for preforming the polystyrene beads. The method further includes the step of heating the preformed polystyrene beads for a predetermined duration and at a predetermined temperature in a state where they are arranged in a mesh shape to season the preformed polystyrene beads. The method further includes the step of transferring the seasoned polystyrene beads into one of a modular platform mold (70) and a leg mold (200). The method includes the step of molding the seasoned polystyrene beads filled inside the modular platform mold (70) and the leg mold (200) to produce a platform section of the EPS pallet and a leg support section of the EPS pallet, respectively. The method further includes the step of stabilizing at least one of the antifungal component and the flame retardant present in the molded platform section and the molded leg support section by drying at a preset temperature and duration. The method further includes the step of dusting the dried platform section and the leg support section by passing them through a dust removal chamber. The method further includes the step of attaching one or more leg support sections to the bottom side of the platform section at a predetermined location to form an EPS pallet.

[0013] To further clarify the advantages and features of the present invention, a specific description of the present invention with reference to specific embodiments of the present invention follows. These embodiments are shown in the accompanying drawings. It should be understood that these drawings only show typical embodiments of the present invention and should not be construed as limiting the scope of the present invention. The present invention will be disclosed and described with additional features and details with reference to the accompanying drawings.

[0014] The present disclosure will be described and explained with additional characteristics and details with reference to the accompanying drawings.

Brief Description of the Drawings

[0015]

Figure 1a

Figure 1b

Figure 1c

Figure 1d

Figure 1e

Figure 1f

Figure 1g

Figure 2a

Figure 2b

Figure 2c

Figure 2d

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0016] Furthermore, as will be understood by those skilled in the art, the elements in the figures are described for clarity and may not necessarily be drawn to scale. Further, in terms of the configuration of the device, one or more components of the device are illustrated with conventional symbols, and the figures show only specific details appropriate for understanding the embodiments of the present invention so as not to obscure details that would be readily apparent to those skilled in the art who benefit from the description herein.

[0017] For the purpose of facilitating understanding of the principles of the present invention, reference is now made to the illustrated embodiments, and specific terms are used to describe the embodiments. Nevertheless, it should be understood that it is not intended thereby to limit the scope of the present invention. Such modifications of the illustrated systems and further adaptations and such further uses of the principles of the present invention that would normally occur to those skilled in the art are to be construed as being within the scope of the present invention.

[0018] As used in the original specification, "comprises" (often translated as "has" in the translation), "comprising" or any other variation thereof is intended to cover non-exclusive inclusion, such that a process or method that includes a list of steps includes these steps but may also include other steps not explicitly listed or inherent to such process or method. Similarly, one or more devices or subsystems or elements or structures or components following "comprises...a" do not exclude the presence of other devices, subsystems, elements, structures, components, additional devices, additional subsystems, additional elements, additional structures or additional components, and this is without any conditions attached. Throughout this specification, phrases such as "in one embodiment", "in another embodiment" and similar expressions may all refer to the same embodiment but not necessarily so.

[0019] Unless otherwise specified, the technical and scientific terms used in this specification have the same meaning as commonly understood by those skilled in the art related to the present invention. The systems, methods, and examples provided herein are merely illustrative and do not limit the present invention.

[0020] In the following description and claims, reference is made to the number of terms, which are to be construed as having the following meanings. The singular forms “a,” “an,” and “the” as used in the original specification include the plural form unless the context clearly dictates otherwise.

[0021] Embodiments of the present invention relate to a set of molds for manufacturing EPS pallets and a method for manufacturing the same. The term “pallet” as used herein is defined as the structural basis of a unit load that enables high handling and storage (warehousing) efficiency. The EPS pallet described herein includes a platform section and one or more leg sections. The set of molds includes a modular platform mold and a leg mold configured to manufacture the platform section and one or more leg sections of the EPS pallet, respectively. The platform mold and the one or more leg molds are described as modular because each of the platform mold and the leg mold can be designed and changed according to desired specifications to result in platform sections and leg support sections of various dimensions.

[0022] Figures 1a - 1f show a modular platform mold 70 according to an embodiment of the present invention. Figures 1a and 1b are cross-sectional side views of the modular platform mold 70 according to an embodiment of the present invention. The modular platform has a bottom plate 80 of a predetermined dimension, where the predetermined dimension may be determined according to industrial requirements. In one embodiment, the bottom plate 80 preferably has walls of a predetermined height located at all edges of the bottom plate 80, thereby creating a hollow space 90 within the inner boundary of the walls. In some embodiments, the dimensional shape of the platform of the hollow bottom plate 80 may be in the shape of a square, rectangle, etc.

[0023] The bottom plate has a first set of a plurality of openings 140a configured to receive a polystyrene bead supply and guide the polystyrene beads into the hollow space 90, thereby forming the platform section of the EPS pallet.

[0024] The bottom plate further has a second set of a plurality of openings configured to allow the inflow of at least one of air, water, and steam and allow the outflow of water. The second set of a plurality of openings is provided with valves configured to allow one-way flow.

[0025] The modular platform mold further has a top plate 100 of a predetermined dimension configured to fit on top of the hollow bottom plate 80 to form the hollow space 90. The dimensions of the hollow space 90 match the dimensions of the platform section of the EPS pallet. Specifically, the top plate 100 preferably has a plurality of edges corresponding to the dimensional shape of the walls of the hollow bottom plate 80. Therefore, the walls of the hollow bottom plate 80 and the bottom surface of the top plate 100 are joined together to keep the hollow space 90 intact.

[0026] In one embodiment, the bottom plate has a third set of a plurality of openings configured to allow the inflow of at least one of air, water, and steam and to allow the outflow of water. The plurality of openings forming the second set are provided with valves configured to allow one-way flow.

[0027] The air, water, and steam supplied through the plurality of openings forming the second set and the plurality of openings forming the third set are pressurized in the modular platform mold 70 to cause foaming of the polystyrene beads in the hollow space 90.

[0028] The modular platform mold further has modular units (110a, 110b) shown in FIGS. 1c, 1d, 1e, 1f, and 1g according to an embodiment of the present invention. The modular units (110a, 110b) are configured to change the dimensional shape of the hollow space 90.

[0029] FIG. 1c is a plan view of the modular platform mold including the modular unit, and the top plate is omitted to show the internal arrangement state. Further, FIG. 1e is a plan view of the modular platform mold including the modular unit, and the top plate is arranged on the bottom plate. FIG. 1f is a bottom view showing the arrangement state of the modular platform mold and the modular unit. FIG. 1g is a cross-sectional side view showing the arrangement state of the modular platform mold and the modular unit.

[0030] The modular unit includes a first elongated panel 110a having one or more first segments 120a. The first elongated panel 110a is longitudinally oriented on a first side of the bottom plate 80 and is received within the hollow space 90. In one embodiment, the one or more first segments 120a are removably attached units, and the lengths of the removably attached segments may vary. For example, the one or more first segments can include one long segment and other small segments. Further, the small segments are preferably configured to be "Z"-shaped, thereby enabling simultaneous and independent movement of the one or more first segments 120a depending on the push or pull position.

[0031] Each of the one or more first segments 120a is configured to operate laterally and independently to move from a first position to a second position, thereby changing the length of the hollow space 90. FIGS. 1c and 1d show the movement of the first segment 120a from the first position to the second position. However, the distance between the first position and the second position may vary according to requirements. In one embodiment, each of the one or more first segments 120a is preferably configured to be operated laterally and independently to move longitudinally from a first position to a second position by a first set of levers 130a. One or more of the first set of levers 130a are provided for the corresponding one or more first segments 120a and are configured to push or pull the corresponding one or more first segments 120a. Specifically, each of the one or more first segments 120a is operatively coupled to a corresponding lever of the first set of levers 130a to laterally operate the corresponding segment longitudinally for the purpose of changing the length of the hollow space 90.

[0032] For example, the first elongated panel 110a may have a segment "A" and a segment "B", and when the segment A and the segment B are combined, a first elongated panel is formed that is disposed across the length of the hollow space on the hollow bottom plate. Assuming that the modular unit has a lever "E" and a lever "F", in this case, the lever E may be operatively coupled to the segment A along its length for lateral operation of the segment A. Similarly, the lever F may be operatively coupled to the segment B along its length to enable lateral operation of the segment B along the length of the hollow space. Further, the levers E and F are automatically actuated to enable the respective movements of the segment A and the segment B based on requirements regarding changes in the length dimension of the hollow space. Further, based on the required length, the segment A and the segment B may be laterally moved across the length of the hollow space from a first position to a second position, thereby obtaining a platform mold of the required length.

[0033] In one exemplary embodiment, the first set of levers 130a is coupled to the corresponding one or more first segments 120a from outside the wall of the hollow bottom plate 80. Each of the first set of levers 130a penetrates through the wall to contact the corresponding one or more first segments 120a.

[0034] Similarly, the modular unit further includes a second elongated panel 110b having one or more second segments 120b. The second elongated panel 120b is oriented in the width direction on the second side of the hollow bottom plate 80 while being housed within the hollow space 90. Each of the one or more second segments 120b is configured to be independently operated laterally to move from a first position to a second position, thereby changing the width of the hollow space 90. FIGS. 1c and 1d show the movement of the first segment 120b from the first position to the second position. However, the distance between the first position and the second position may vary according to requirements.

[0035] As a continuation of the above embodiment, assume that the second elongated panel has segments "C" and "D", and by combining segment C and segment D, a second elongated panel is formed that is disposed across the width of the hollow space on the hollow bottom plate. Assume that the modular unit has levers "G" and "H", and lever G may be operatively coupled along its width to segment C so as to enable lateral operation of segment C. Similarly, lever H may be operatively coupled along its width to segment D to enable lateral operation of segment D along the width of the hollow space. Further, levers G and H are automatically actuated to enable the respective movements of segment C and segment D based on the requirement for changing the width dimension of the hollow space. Further, based on the required width, segment C and segment D may be laterally moved across the width of the hollow space from a first position to a second position, thereby obtaining a platform mold of the required width.

[0036] It is clear that the first elongated panel (110a) and the second elongated panel (110b) together define the dimensions of the hollow space.

[0037] The opening and closing of the plurality of openings forming the first set, the plurality of openings forming the second set, and the plurality of openings forming the third set are controlled by a programmable system. Further, the movement of the lever (130a) forming the first set and the lever (130b) forming the second set is also controlled by a programmable system according to the dimensions of the platform section and the leg support section provided as inputs.

[0038] In one embodiment, one or more of the plurality of openings forming the first set are configured to be in an active state only when positioned to guide a polystyrene bead supply in accordance with the modified dimensions of the hollow space. For example, a scenario is envisioned where the dimensions of the hollow space are modified to be small, such that as a result, one of the three openings may accidentally be located outside the hollow space. In such a scenario, in this case, the opening outside the hollow space should not be put in an active state.

[0039] In another embodiment, the set of molds for fabricating an EPS pallet further includes a leg mold (70) configured to act as a mold for fabricating a plurality of leg support sections corresponding to the platform section of the EPS pallet.

[0040] Figures 2a - 2d show the structure of the leg mold as viewed from various perspectives in accordance with the present invention.

[0041] Figures 2a and 2b are respectively a front sectional view and a rear sectional view of a leg mold. In one embodiment, the leg mold may have a bottom layer 150, an intermediate layer 160, and a top layer 190 that are stacked on top of each other in a nested state. The bottom layer 150 may be configured to surround the intermediate layer 160. Specifically, the intermediate layer 160 may be disposed on top of the bottom layer 150 in such a way that the dimensions of the bottom layer 150 and the intermediate layer 160 match each other. Further, the intermediate layer 160 has a plurality of hollow cavities 170 of a predetermined dimension. Each of the plurality of hollow cavities 170 may be fabricated at a predetermined distance from adjacent hollow cavities within the intermediate layer 160. The top layer 190 is configured to fit on top of the intermediate layer 160 with the openings of the plurality of hollow cavities in the intermediate layer sealed. The plurality of hollow cavities 170 are configured to receive a polystyrene bead supply and create a leg support section. In one particular embodiment, the intermediate layer 160 may be configured to act as a female cavity opening, and the top layer 190 may be configured to act as a male enclosure for the female cavity.

[0042] In one embodiment, the bottom layer (150) has a plurality of inlets for air, water, and steam or combinations thereof, one or more outlets for removing water, and one or more openings for receiving a polystyrene bead supply.

[0043] In another embodiment, the top layer (190) has a plurality of inlets for air, water, and steam or combinations thereof, and one or more outlets for removing water.

[0044] The air, water, and steam supplied through the plurality of inlets of the top and bottom layers are pressurized within the leg mold to cause foaming of the polystyrene beads within the plurality of hollow cavities 170 and create a plurality of leg support sections.

[0045] In another embodiment, the leg mold may further have an external fixture in the form of one or more rings. Each of the one or more rings fits inside a plurality of hollow cavities, thereby changing the dimensions of the plurality of hollow cavities and thereby configured to produce a plurality of leg support sections of the changed dimensions. The one or more rings may be of a shape and height that tapers to cause a corresponding change in the shape of the plurality of leg support sections.

[0046] Furthermore, the rings may be attached or removed manually or by mechanical means, such as a robotic arm.

[0047] The platform section and the leg support section of the EPS pallet are configured to be attached to each other at a predetermined position according to the dimensional shape and load-bearing capacity of the platform to obtain an EPS pallet mold.

[0048] In one embodiment, a method of manufacturing a set of molds for manufacturing an EPS pallet is provided. FIG. 3 is a flowchart showing the steps of a method 300 of manufacturing a set of molds for manufacturing an EPS pallet according to an embodiment of the present invention. Each of the multiple sets of molds is manufactured in the same procedure as described below with reference to FIG. 3. The set of molds includes a modular platform mold and a leg mold. In one embodiment, the set of molds for the EPS pallet is made using the case aluminium method.

[0049] The method includes, at step 310, the step of drawing a plurality of patterns for the base of one of the modular platform mold (70) and the leg mold (200). The plurality of patterns includes a plurality of rib locations, a plurality of supply locations, and steam jet intervals. As used herein, a rib location is a thin-walled structure that increases the support action and rigidity of an injection molded part.

[0050] Method 10 further includes, at step 320, separately and independently fabricating each of the plurality of patterns using one of wood or expanded polystyrene (EPS). In one embodiment, the pattern may be achieved / fabricated using the lost foam technique. The lost foam technique is a kind of lost mold casting method where the lost foam is used for the casting process.

[0051] Method 10 further includes, at step 330, casting each of the plurality of fabricated patterns. In one embodiment, the casting of the fabricated pattern can be carried out using LM24 together with carbon sand. LM24 is a pressure die-cast aluminum alloy with excellent casting properties. Therefore, LM24 can be used for the casting of a set of pallet molds. In a particular embodiment, the set of molds may be fabricated using a computer numerical control (CNC) machine. The CNC machine is equipped with a number of tools and 3D printers for processing materials to fit the desired article without human intervention. Therefore, the CNC machine can be used to process and fabricate the set of molds. When obtaining the set of molds, one or more space jets are attached based on the low-temperature cooler bag requirements of the EPS pallet.

[0052] Furthermore, method 10 for obtaining the set of molds includes, at step 340, polishing the plurality of cast patterns using a buffing method. The polishing of the cast patterns is achieved to smooth the plurality of cast patterns and obtain a finished set of molds for the EPS pallet. The above-described method 10 is implemented to obtain a modular platform mold and a leg mold. When obtaining these, at step 350, one or more of the cast patterns of the plurality of polished patterns are combined to obtain one of the modular platform mold (70) and the leg mold (200).

[0053] In one exemplary embodiment, method 10 includes a Teflon coating method in which one or more of the critical shape inserts are utilized in a mold set to facilitate rapid cooling and removal. In one exemplary embodiment, it may be desirable to fabricate a number of fixtures configured to change the dimensions of the modular platform mold. The number of fixtures may be made of brass for long life or good cooling. The plurality of polished patterns includes a modular platform mold and a leg mold. The platform section, together with the leg section, forms an EPS pallet mold. Once an EPS pallet mold of the desired specifications and dimensions is obtained, an EPS pallet is fabricated.

[0054] In another embodiment, a method for manufacturing an EPS pallet using a modular platform mold (70) and a leg mold (200) is provided. FIG. 4 is a flowchart depicting the steps of a method 400 for manufacturing an EPS pallet according to an embodiment of the present invention.

[0055] Method 400 includes, at step 410, mixing polystyrene beads with at least one of one or more antifungal components and one or more flame retardants for preforming the polystyrene beads. In one embodiment, at least one antifungal component may be in the form of a flame retardant grade powder. One or more EPS raw materials may be in the form of granules. When the two components are mixed, antifungal properties are imparted to the EPS pallet.

[0056] Method 400 includes, in step 420, heating the preformed polystyrene beads in a meshed state over a predetermined duration and at a predetermined temperature to season the preformed polystyrene beads. The preformed material is placed in a nylon mesh silo and heated at about 45 °C for about 2 - 4 hours, preferably 3 hours. Since the mixture may lose its antifungal property at temperatures exceeding 45 °C, it is important that the temperature be maintained at a constant rate to obtain the seasoned material.

[0057] Further, method 400 includes, in step 430, transferring the seasoned polystyrene beads into one of a modular platform mold (70) and a leg mold (200).

[0058] In another embodiment, the method may further include the step of molding and adding inserts to give additional strength to the EPS pallet. This method may be employed based on the pattern design. In such an embodiment, molding the insert may include molding one of a metal wire mesh, a plate, an angle, a corner, a rod, etc. The insert may be composed of a metal, such as non-corrosive steel and its alloys, that can increase the load-bearing capacity of the EPS pallet to about 7 - 8 tons. In some embodiments of the present invention, the specially made fixture insert further includes wheels that can move easily to obtain specific requirements of the pallet.

[0059] A method 400 for manufacturing an EPS pallet may further include, at step 440, a step of molding seasoned polystyrene beads filled inside a modular platform mold (70) and a leg mold (200) to form a platform section of the EPS pallet and a leg support section of the EPS pallet, respectively. In one embodiment, the molding process may include a steam molding process. In this case, the seasoned material is filled into the mold set through a supply point of the mold set via a molding machine, and then steam is applied to the seasoned material for a predetermined time at a specific pressure level.

[0060] When the desired time interval is reached, the material in the mold set that is under steam is cooled or dried. Specifically described, method 400 includes, at step 450, a step of stabilizing at least one type of antifungal component and flame retardant present in the molded platform section and the molded leg support section by drying at a preset temperature and duration. The drying of the molded pallet is achieved by placing the mold set in a drying chamber at a temperature of about 45 °C for a time of about 4 hours or less, the purpose of which is to maintain the antifungal property of the molded pallet. In one exemplary embodiment, the drying may be achieved by placing the molded pallet in a specially designed drying chamber. Once the material in the mold set is dried, the molded pallet is demolded from the mold set to obtain a pallet of the desired dimensions.

[0061] Method 400 includes, at step 460, a step of dust-removing the dried platform section and leg support section by a dust-removing chamber to enhance the finish of the EPS pallet. The dust-removing process is carried out to clean the surface and remove particles as foreign matter from the demolded pallet.

[0062] Method 400 further includes attaching one or more leg support sections to the bottom side of the platform section at a predetermined location to form an EPS pallet. The predetermined location for attaching the one or more leg support sections to the platform section is determined based on the load-bearing capacity and the location for lifting the EPS pallet.

[0063] According to various embodiments of the present invention, a set of molds for manufacturing a pallet and a method for manufacturing the same are enabled when reducing the overall capital cost in a unique way of dividing a mold into two or more parts, and by later joining the parts of the mold together with a specific adhesive, easy customization for the size (dimensions) of the mold can be implemented. The base of the mold is designed with reinforcing ribs, supply locations, and steam jet intervals. By using a single mold structure having segments for changing the mold size, easy customization to various sizes according to the requirements of the client relaxes the requirement to stock various molds for different dimensions. Also, the space requirement for the mold is relaxed, because it is not necessary in the present invention to hold casting molds for various sizes and various dimensions.

[0064] In addition, the load-bearing capacity of the EPS pallet can be increased by inserting inserts in the form of wires, meshes, inserts, plates, angles, corners, rods, etc. according to the design requirements for increasing the load-bearing capacity of the pallet to about 7 to 8 tons. Also, the base material coating of the pallet makes this method economical and effective for coating. By using a specific blend of polyurea, polyurethane, and silicone elastomer, desired properties such as impact resistance and abrasion resistance, flexural or tensile strength, and antistatic properties can be imparted together with impact resistance and flexural strength. The base material coating provides a very strong bond due to the overlap on the sides and reduces waste of the coating material. The method also reduces the scattering of coating particles and increases productivity. Also, due to the use of an adhesive for bonding a number of molds, there is no additional unit for bonding these molds, thereby making the set of molds robust for any purpose. Also, the pallet produced by the set of molds remains a single part, thereby making the handling of such a pallet more convenient. Therefore, such a method of producing a modular set of molds or a pallet is more reliable.

[0065] The present invention has been described using specific terms, but no limitation is intended by the use of such terms. As will be apparent to those skilled in the art, various operational modifications can be made to the method to embody the inventive concept taught herein.

[0066] The various figures and the above description provide examples with respect to embodiments. As will be understood by those skilled in the art, one or more of the elements described above can be skillfully combined into a single functional element. As a variant, a particular element may be divided into a number of functional elements. Elements taken from one embodiment can be added to another embodiment. For example, the order of the method steps described herein can be changed, and this is not limited to the manner described herein. Further, the operations of any flowchart need not be performed in the order shown, and not all of the operations need necessarily be performed. Also, operations that do not depend on other operations can be performed in parallel with other operations. The scope of the embodiments is not limited in any way by these specific examples.

Claims

1. A set of molds for manufacturing an EPS pallet, comprising: a modular platform mold (70) configured to function as a mold for the platform section of the EPS pallet, the modular platform mold comprising: a bottom plate (80) of a predetermined dimension; a top plate (100) of a predetermined dimension, the top plate being configured to fit on the bottom plate (80) with a hollow space (90) corresponding to the dimensions of the platform section of the EPS pallet formed between the top plate (100) and the bottom plate (80), the hollow space (90) being configured to receive a polystyrene bead supply; a modular unit configured to change the dimensions of the hollow space, the modular unit comprising: a first elongated panel (110a) having a plurality of first segments (120a), the first elongated panel (110a) being longitudinally oriented on a first side of the bottom plate (80) and received within the hollow space (90), each of the plurality of first segments being operable independently laterally to move from a first position to a second position, thereby configuring the length of the hollow space (90) to be changed; a second elongated panel (110b) having one or more second segments (120b), the second elongated panel (110b) being laterally oriented on a second side of the bottom plate (80) while being received within the hollow space (90), each of the one or more second segments (120b) being operable independently laterally to move from a first position to a second position, thereby configuring the width of the hollow space (90) to be changed. A set of molds.

2. The bottom plate has a first set of a plurality of openings configured to receive the polystyrene bead supply and guide the polystyrene beads into the hollow space (90), thereby forming the platform section of the EPS pallet. A set of molds for manufacturing an EPS pallet according to Claim 1.

3. One or more of the plurality of openings forming the first set are configured to be in an active state when positioned to guide the polystyrene bead feed in accordance with the modified dimensions of the hollow space. A set of molds for manufacturing an EPS pallet according to claim 2.

4. The bottom plate has a plurality of openings forming a second set configured to allow the entry and exit of at least one of air, water, and steam. A set of molds for manufacturing an EPS pallet according to claim 1.

5. The top plate has a plurality of openings forming a third set configured to allow the entry and exit of at least one of air, water, and steam. A set of molds for manufacturing an EPS pallet according to claim 1.

6. Each of the plurality of first segments (120a) is configured to be operated independently laterally to move from the first position to the second position by a corresponding first set of levers (130a), and one or more of the first set of levers are provided for the corresponding plurality of first segments (120a) and are configured to push or pull each of the plurality of first segments (120a). A set of molds for manufacturing an EPS pallet according to claim 1.

7. Each of the one or more second segments (120b) is configured to be operated independently along the length direction along the second side portion within the hollow space (90) by a corresponding second set of levers (130b), and one or more of the second set of levers (130b) are provided for the corresponding one or more second segments (120b) and are configured to push or pull each of the one or more second segments (120b) to obtain a desired dimension of the hollow space. A set of molds for manufacturing an EPS pallet according to claim 1.

8. The set of molds further includes a leg mold (70) configured to act as a mold for manufacturing a plurality of leg support sections corresponding to the platform section of the EPS pallet. The leg mold has a bottom layer (150) with a plurality of inlets for at least one of air, water, and steam, one or more outlets, and one or more openings for receiving a polystyrene bead feed. It has an intermediate layer (160) with a plurality of cavities of a predetermined dimension, and the bottom side of the intermediate layer (160) is configured to cover the top side of the bottom layer (150). It has a top layer (190) with a plurality of inlets and one or more outlets for at least one of air, water, and steam, and the top layer is configured to fit over the top side of the intermediate layer (160) while sealing the plurality of hollow cavities of the intermediate layer. The plurality of sealed hollow cavities are configured to receive the polystyrene bead supply through the one or more openings of the bottom layer (150) and shape the plurality of leg support sections. A set of molds for manufacturing an EPS pallet according to claim 1.

9. The leg mold further has one or more rings configured to fit into the interior of the plurality of hollow cavities, thereby changing the dimensions of the plurality of hollow cavities for manufacturing the plurality of leg support sections of the modified dimensions. A set of molds for manufacturing an EPS pallet according to claim 8.

10. A method (300) for manufacturing a set of molds for manufacturing an EPS pallet, including the step of drawing a plurality of patterns for the base of one of the modular platform mold (70) and the leg mold (200), the patterns including a plurality of rib locations, a plurality of supply locations, and steam jet intervals. including the step of separately manufacturing each of the plurality of patterns using one of wood or expanded polystyrene (EPS). including the step of casting each of the plurality of manufactured patterns. including the step of polishing the plurality of cast patterns using a buffing method. A method (300) including the step of combining one or more of the cast patterns of the plurality of polished patterns to obtain one of the modular platform mold (70) and the leg mold (200).

11. A method (400) for manufacturing an EPS pallet, including the step of mixing polystyrene beads with at least one of one or more antifungal components and one or more flame retardants for preforming the polystyrene beads. including the step of heating the preformed polystyrene beads over a predetermined duration and at a predetermined temperature while the preformed polystyrene beads are arranged in a mesh-like state to season the preformed polystyrene beads. transferring the seasoned polystyrene beads into one of a modular platform mold (70) and a leg mold (200); molding the seasoned polystyrene beads filled inside the modular platform mold (70) and the leg mold (200) to form a platform section of the EPS pallet and a leg support section of the EPS pallet, respectively; stabilizing by drying at a preset temperature and duration the at least one antifungal component and flame retardant present in the molded platform section and molded leg support section; dust-removing the dried platform section and leg support section by passing them through a dust-removing chamber; a method for manufacturing an EPS pallet, comprising attaching one or more leg support sections to a bottom side portion of the platform section at a preset location to form the EPS pallet.

12. The method for manufacturing an EPS pallet according to claim 11, wherein the preset temperature for heating the preformed polystyrene beads is 45°C.

13. The method for manufacturing an EPS pallet according to claim 11, wherein the preset duration for heating the preformed polystyrene beads is 3 hours.

14. The method for manufacturing an EPS pallet according to claim 11, wherein the preset temperature for drying is 45°C.

15. The method for manufacturing an EPS pallet according to claim 11, wherein the preset duration for drying is 2 to 4 hours.

16. The method for manufacturing an EPS pallet according to claim 11, wherein the preset location for attaching the one or more leg support sections to the platform section is determined based on a load-bearing capacity and a position for lifting the EPS pallet.

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