Composite pallet, method for forming a composite structural component, method for forming a composite pallet

Abstract

A composite pallet having a top surface, a bottom surface, and at least one forklift opening located between the bottom and top surfaces; wherein at least a portion of the pallet is formed from a composite material including filter media and a cured resin. A method for forming a composite structural component can include providing filter media material including one or both of cellulosic fibers and synthetic fibers; mixing the filter media material with a liquid resin material; placing the mixture of filter media material and liquid resin material into a mold; allowing the mixture to cure to form a structural member; and removing the structural member from the mold.

Description

COMPOSITE PALLET, METHOD FOR FORMING A COMPOSITE STRUCTURAL COMPONENT, METHOD FOR FORMING A COMPOSITE PALLETRelated Application

[0001] This application claims priority to United States Provisional Patent Application Serial Number 63 / 585,441 filed on September 26, 2023, the entirety of which is incorporated by reference herein.Technical Field

[0002] This disclosure relates to structures formed from recycled materials, and more particularly to structures, such as pallets, using structural members formed from recycled filter media.Background

[0003] Pallets are well-known structures used for supporting various goods and loads during transport operations. Many materials have been used to form such pallets, such as wood, plastic, and composite materials. Improvements are desired.Summary

[0004] Manufacturing processes often generate waste as a byproduct of creating finished goods or products. This waste can take various forms, including raw material scraps, defective products, packaging materials, and chemical residues. As production occurs, these waste materials accumulate and are typically collected and transported to designated landfills. Sending such waste to landfills has a number of well-known disadvantages, including negative environmental impacts, resource depletion, increased land use, health risks, energy waste, and missed economic opportunities.

[0005] In one particular example, a filter cartridge manufacturing plant can generate up to 2.4 million pounds of filter media scrap material in a single year while simultaneously having an annual need for about 100,000 pallets for shipping finished filtration products. In the present disclosure, a highly advantageous solution is proposed in which filter media scrap material and other waste components, such asunused cyanate, is recycled into composite structural members that are particularly well suited for use in manufacturing pallets having a similar service life as traditionally manufactured pallets. With such an approach, the filter media scrap material generated by a filter cartridge manufacturing plant can be recycled to form about half of the pallets needed by the plant to ship finished filtration products. Accordingly, the proposed approach virtually eliminates the need to transport and dispose of filter scrap media at a landfill while significantly reducing raw material usage required for building a significant number of pallets, thereby greatly increasing sustainability of the filter cartridge manufacturing process.

[0006] A composite pallet can include a top surface, a bottom surface, and at least one forklift opening located between the bottom and top surfaces, wherein at least a portion of the pallet is formed from a composite material including filter media and a cured resin.

[0007] In some examples, the top surface is defined by a plurality of top deckboards formed from the composite material.

[0008] In some examples, the bottom surface is defined by a plurality of bottom deckboards formed from the composite material.

[0009] In some examples, the pallet further comprises a plurality of stringers formed from the composite material.

[0010] In some examples, each of the plurality of top deckboards and each of the plurality of bottom deckboards are secured to the plurality of stringers via fasteners.

[0011] In some examples, the cured resin includes isocyanate.

[0012] In some examples, the filter media includes cellulose fibers.

[0013] In some examples, the filter media includes synthetic fibers.

[0014] In some examples, the filter media is shredded filter media.

[0015] In some examples, the filter media has a thickness between about .005 inch and about .030 inch.

[0016] A method for forming a composite structural component can include providing filter media material including one or both of cellulosic fibers and synthetic fibers; mixing the filter media material with a liquid resin material; placing the mixture of filter media material and liquid resin material into a mold; allowing the mixture to cure to form a structural member; and removing the structural member from the mold.

[0017] In some examples, the liquid resin material includes isocyanate.

[0018] In some examples, the step of providing filter media material includes processing the filter media material to have an average size of about 1 to 6 inches in length.

[0019] A method for forming a composite pallet can include providing filter media material including one or both of cellulosic fibers and synthetic fibers; mixing the filter media material with a liquid resin material; placing the mixture of filter media material and liquid resin material into a mold; allowing the mixture to cure to form a structural member; removing the structural member from the mold; and securing a plurality of the structural members together to form a pallet structure having at least one forklift opening.

[0020] In some examples, the liquid resin material includes isocyanate.

[0021] In some examples, the step of providing filter media material includes processing the filter media material to have an average surface area, on one side, of between about .75 and about 6 square inches.

[0022] In some examples, the step of securing a plurality of structural members together includes securing a plurality' of top deckboards to a plurality of stringers.

[0023] In some examples, the step of securing a plurality of structural members together includes securing a plurality of bottom deckboards to a plurality' of stringers.

[0024] In some examples, the pallet structure has two forklift openings.

[0025] In some examples, the pallet structure is formed to have a single-piece construction.

[0026] A variety of additional aspects will be set forth in the description that follow s. The aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the examples disclosed herein are based.Brief Description of the Drawings

[0027] The present invention will be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views.

[0028] Figure 1 is a perspective view of a pallet having features in accordance with the present disclosure, the pallet shown as supporting a plurality' of boxed goods.

[0029] Figure 2 is a perspective view' of the pallet of Figure 1.

[0030] Figure 3 is a perspective view of a portion of the pallet shown in Figure 1.

[0031] Figure 4 is a perspective view of a load testing apparatus demonstrating load testing of a deckboard of the pallet of Figure 1.

[0032] Figure 5 is a flow' chart showing a process for forming components of the pallet shown in Figure 1.

[0033] Figure 6 is a perspective view of unprocessed filter media scrap material usable to form the pallet shown in Figure 1.

[0034] Figure 7 is a perspective view of processed filter media scrap material formed by shredding the unprocessed filter media scrap material shown in Figure 1.

[0035] Figure 8 is a perspective view of the processed filter media scrap material shown in Figure 7, placed into a mold with other materials to form a recycled composite board.

[0036] Figure 9 is a perspective view' of a plurality of deckboards usable to form the pallet of Figure 1, the plurality of deckboards being cut from a recycled composite board formed within the mold shown in Figure 8.Detailed Description

[0037] Referring to Figure 1, a pallet 100 is shown that can support a wade variety of goods and loads, such as a plurality of boxed goods 10. In one aspect, and as explained in further detail below, the pallet 100 can be formed from a recycled material that includes a recycled filter media material.

[0038] Referring to Figures 1 and 2, one example of a pallet 100 formed from a recycled filter media material having features in accordance with the present disclosure is presented. Referring to Figure 2, the pallet 100 is shown as being formed with a first outer stringer or runner 102. a center stringer 104. and a second outer string or runner 106. The pallet 100 is further shown as being formed with aplurality of top deckboards 108, defining a top surface 100a of the pallet 100, secured on one side of the stringers 102, 104, 106 and a plurality of bottom deckboards 110. defining a bottom surface 100b of the pallet 100, secured on the opposite side of the stringers 102, 104, 106. In one aspect, the pallet 100 is formed such that at least two forklift openings 100c are formed between the top and bottom surfaces 100a, 100b. In the example shown, the pallet 100 is formed from three stringers, seven top deckboards, and seven bottom deckboards to form a pallet that is about 40 inches wide, 48 inches long, and 6 inches tall. However, other pallet sizes and other numbers of stringers and deckboards may be used without departing from the concepts disclosed herein. Further, many other types of pallets can be formed using the disclosed recycled filter media material in accordance with the present disclosure, such as pallets that are molded to have a single-piece construction having the same general shape as shown in Figures 1 and 2, or with another shape.

[0039] As illustrated at Figure 3, the deckboards 108, 110 can be secured to the stringers 102, 104, 106 with fasteners 112. configured as screws. Other types of fasteners may be used, such as nails and staples. Advantageously, traditional pallet construction fasteners and techniques can be used to secure deckboards 108, 110 to the stringers 102, 104, 106.

[0040] Referring to Figure 4, a load testing apparatus is shown demonstrating that each of the deckboards 108, 110. formed from a recycled filter media material, have sufficient structural integrity to support a 25-pound load TL with little or no deflection. Consequently, a pallet 100 can be formed from a recycled filter media material with sufficient strength to meet various structural requirements. For example, pallet 100 can be configured as a rigid horizontal platform of minimum height, compatible with handling by pallet trucks and / or forklift trucks and other appropriate handling equipment, used as a base for assembling, loading, storing, handling, stacking, transporting, or displaying goods and loads, in accordance with ISO (the International Organization for Standardization) 445:2013 and 18334:2010.

[0041] Referring to Figure 5, a process 1000 is disclosed that is suitable for forming structural members, for example, the individual stringers 102, 104, 106 and deckboards 108, 110. While the disclosed method is described in relation to forming members used in a pallet application, the disclosed method may be used to form structural members for many other applications. For example, the disclosed method may be utilized to form fully finished articles and articles other than sheet or boardstock having non-rectangular shapes. In addition to pallets, the disclosed method may be also used to form many other types of structures, such as dunnage trays, shipping boxes and crates, gaylords, skids, and / or intermediate bulk containers.

[0042] In a first step 1002, scrap filter media material 50 is provided, as further illustrated at Figure 6. By use of the term “filter media” it is meant to include permeable sheet materials suitable for use in filtration applications, such as sheet materials having a MERV (Minimum Efficiency Reporting Value) rating between 1 and 20 and / or an ISO (International Standards Organization) 5011 efficiency rating of at least 90% or higher. Examples of filter media are substrates including one or both of cellulose and sy nthetic fibers. In some examples, the filter media additionally includes fine fibers, such as 0.2 to 0.3 micron fine fibers. In some examples, the filter media includes a binder such as latex, resin, or an adhesive that is used to bind the media fibers. In some examples, the filter media includes one or more of wet strength additives, antimicrobial agents, flame retardants, fillers, and / or surface treatments. In some examples, the filter media has a thickness between about .005 inch and about .030 inch, and more typically between about .007 inch and about .015 inch. Commercial examples of filter media are Donaldson High-efficiency Cellulose Media, Donaldson Ultra-Web® Media, Donaldson Ultra-Web® HD Media, and Donaldson Synteq Synthetic Media provided by Donaldson Company, Inc. of Minnesota. USA. The filter media may be. for example, media used for air filtration or liquid filtration. By use of the term “scrap filter media” it is meant to include discarded or excess filter media material generated in the course of a filter manufacturing process. Scrap filter media material at step 1002 may be referred to as being unprocessed. One example of unprocessed scrap filter media material is shown at Figure 6.

[0043] In a step 1004, the unprocessed scrap filter media material is shredded or otherwise reduced to a desired size and / or shape to become processed / recycled scrap filter media material 52. as further illustrated at Figure 7. In some examples, the scrap filter media is shredded to have an average size between about 1 and 6 inches in length and about .5 and 1.5 inches in width. One example of processed / recycled scrap filter media material is show n at Figure 7 in which the media material has been shredded to have an average size of about 3 to 4 inches in length and about 1 inch in width. In examples, the scrap filter media has been shredded to have an averagesurface area on one side of between .75 square inches and 6 square inches, for example an average area of about 3 to 4 square inches.

[0044] In a step 1006, a liquid resin material is provided. In one example, the liquid resin material is a mixture of denatured alcohol, water, and isocyanate forming a liquid urethane material. Such a mixture is advantageous when using scrap fdter media as the constituent materials are already used in many filter manufacturing processes to form seal members of filters cartridges. Further, isocyanate that is expired, non-conforming, or otherwise unsuitable for use in filter manufacturing may still be usable for forming members via process 1000, thereby reducing or even eliminating hazardous waste disposal volumes. Additionally, isocyanate is already used in the construction industry, for example in the formation of laminated strand lumber (LSL) and oriented strand board (OSB). In some examples, the isocyanate is ELASTOFLEX TF-24639T Advhesive manufactured by BASF which may or may not be used in conjunction with a catalyst to control gel time. In some examples, the isocyanate is new, unused isocyanate of the highest grade. In one example, a highspeed paddle type mixer is used to mix the denatured alcohol, water, and isocyanate for 15 to 30 seconds. In one example, the mixture includes 2.2 ounces by weight of denatured alcohol, 15 ounces by weight of water with a temperature between 100°F to 110°F. and 2 pints of isocyanate. Other resin materials can be utilized, such as epoxy resins and cyanoacrylate. In some examples, the resin material and any associated reacting agents are selected such that they will not chemically react with a binder material present in the scrap filter media. In some examples, the resin material and / or associated reacting agents are selected such that they will chemically react with the binder material present in the scrap filter material

[0045] In a step 1008, the processed scrap filter media and the liquid resin material are combined and mixed until the filter media is completely coated by the liquid resin material. In one example, 2 gallons by volume of the processed scrap filter media are combined and mixed with the liquid resin material.

[0046] In a step 1010. the combined processed scrap filter media and liquid resin material are placed as a mixture 54 into a mold, as is illustrated at Figure 8. In some examples, the scrap filter media is oriented within the mold such that the faces of the media are generally parallel to the top and bottom of the mold. In such an arrangement, the scrap filter media can be characterized as being placed in a generally flat or planar orientation. In some examples, a roller or other machinecomponent is utilized to flatten the filter media to provide for the planar or flat orientation of the media either before resin is mixed with the media. In some examples, vibration is utilized during the formation and molding process. In some examples, the scrap filter media is arranged within the mold such that the individual media pieces are generally overlapping with other media pieces and are oriented such that at least some of the scrap filter media pieces are oriented such that they are at different angles along their lengths in comparison to at least some other scrap filter media pieces. In some examples, the lengths of the scrap filter media pieces can be aligned to be generally oriented in the same direction, for example a longitudinal direction of the mold and subsequently formed structural component. In some examples, sufficient scrap filter media is utilized such that the media is completely overlapping across the entire area of the formed structural component such that no ‘line of sight’ opening or gaps exist between the top and bottom sides of the formed structural component. In an alternative approach, steps 1008 and 1010 are performed together such that mixing of the scrap filter media and liquid resin occurs within the mold. In some examples, the mold is provided with nonstick surfaces and / or coated with a mold release agent. In some examples, the mixture is worked such that the scrap media material is overlapping within the mold. In some examples, stiffeners such as wood dowels, can be inserted to increased strength and rigidity of the finished product. In such an example, the mixture can be placed in the bottom half of the mold, after which the stiffeners can be laid into the mold and subsequently covered with the further addition of the mixture to encapsulate the stiffeners. In one example, the mixture is filled into the mold such that the mixture is above the top edge of the mold sides by 1 / 8 inch to 1 / 4 inch.

[0047] In a step 1012, a cover is placed on top of the mold while in a step 1014, the cover is compressed and secured onto the mold. At step 1012, the cover will not initially touch the top sides of the mold as the mixture has been overfilled into the mold. With subsequent compression of the cover, in step 1014, onto the top sides of the mold, the mixture will be compressed within the mold. In some examples, a plurality of clamps, for example, clamps spaced every tw elve inches or less, are used to squeeze the cover of the mold dow n until it mates with the bottom of mold to compressing the scrap media and resin mixture. In some examples, a hydraulic press can be used to achieve the desired compression, which can also be used to keep the cover secured in place while the resin material cures.

[0048] In a step 1016, the liquid resin material is allowed to cure under pressure. In one example, the liquid resin material is allowed to cure for 24 hours. In a step 1018. the cover is removed from the mold. The above-described molding process may be referred to as a compression molding process. Such a process has several advantages, such as improved part quality, enhanced mechanical properties, reduced curing time, and consistency and repeatability. For example, applying pressure during curing helps in achieving better part quality by reducing voids, air bubbles, and improving the resin flow. Applying pressure also ensures that the resin completely fills the mold cavity, resulting in a more homogeneous and consistent product. The application of pressure also helps in increasing the density and reducing the porosity of the cured resin. This leads to improved mechanical properties such as strength, toughness, and dimensional stability of the final molded part. Pressure also assists in accelerating the curing process by promoting better heat transfer within the resin. This allows for faster curing times, increasing production efficiency and reducing overall cycle times. Applying pressure ensures consistent and repeatable results. It helps in maintaining uniform resin distribution, reducing variations between parts, and improving overall process control.

[0049] In a step 1020, the formed structural member is removed from the mold. In a step 1022, the formed structural member is cut to desired dimensions to become a finished structural member 56, as is illustrated at Figure 9. Advantageously, the formed structural members can be cut using the same tools as used in typical pallet formation processes. In one example implementation, the mold is sized to form a 4 foot by 8 foot by .75 inch sheet and subsequently cut into the structural members described herein. One advantage of molding the formed structural member with sheet or sheet-ty pe dimensions is that the molded sheet can be processed with standard cutting and assembly equipment used for formation of pallets and other articles from wood stock. Other molded shapes are possible. For example, various molds can be used to form fully finished parts not requiring cutting or other postmold finishing.

[0050] Once the above-described steps have been completed to form all needed structural members, such as stringers 102, 104, 106 and deckboards 108, 110, finished product such as pallet 100 can be assembled through the use of fasteners, adhesives, and / or by other means. In some examples, the stringers and / or deckboards can be formed, via molding or cutting, with interlocking features such that fastenersare not required, such as is explained in United States Patent 5,461,988, the entirety of which is incorporated herein by reference. Adhesives may also be used.

[0051] Advantageously, once the useful life of the pallet 100 has been completed, the pallet 100 can be ground into a material that is suitable for the formation of a new pallet 100 or for another item.

[0052] The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only by the structures described by the language of the claims and the equivalents of those structures.

Claims

What is claimed is:

1. A composite pallet comprising: a) a top surface; b) a bottom surface; and c) at least one forklift opening located between the bottom and top surfaces; d) wherein at least a portion of the pallet is formed from a composite material including filter media and a cured resin.

2. The composite pallet of claim 1, wherein the top surface is defined by a plurality of top deckboards formed from the composite material.

3. The composite pallet of claim 1 or 2, wherein the bottom surface is defined by a plurality7of bottom deckboards formed from the composite material.

4. The composite pallet of any of claims 1 to 3, further comprising a plurality of stringers formed from the composite material.

5. The composite pallet of claim 4, wherein each of the plurality of top deckboards and each of the plurality of bottom deckboards are secured to the plurality of stringers via fasteners.

6. The composite pallet of any of claims 1 to 5, wherein the cured resin includes isocyanate.

7. The composite pallet of any of claims 1 to 6, wherein the filter media includes cellulose fibers.

8. The composite pallet of any of claims 1 to 7, wherein the filter media includes synthetic fibers.

9. The composite pallet of any of claims 1 to 8, wherein the filter media is shredded filter media.

10. The composite pallet of any of claims 1 to 9, wherein the filter media has a thickness between about .005 inch and about .030 inch.

11. A method for forming a composite structural component comprising: a) providing filter media material including one or both of cellulosic fibers and synthetic fibers; b) mixing the filter media material with a liquid resin material; c) placing the mixture of filter media material and liquid resin material into a mold; d) allowing the mixture to cure to form a structural member; and e) removing the structural member from the mold.

12. The method of claim 11, wherein the liquid resin material includes isocyanate.

13. The method of claim 11, wherein the step of providing filter media material includes processing the filter media material to have an average size of about 1 to 6 inches in length.

14. A method for forming a composite pallet comprising: a) providing filter media material including one or both of cellulosic fibers and synthetic fibers; b) mixing the filter media material with a liquid resin material; c) placing the mixture of filter media material and liquid resin material into a mold; d) allowing the mixture to cure to form a structural member; e) removing the structural member from the mold; and f) securing a plurality of structural members, formed by steps a) to e), together to form a pallet structure having at least one forklift opening.

15. The method of claim 14, wherein the liquid resin material includes isocyanate.

16. The method of claim 14, wherein the step of providing filter media material includes processing the filter media material to have an average surface area, on one side, of between about .75 and about 6 square inches.

17. The method of claim 14. wherein the step of securing a plurality of structural members together includes securing a plurality of top deckboards to a plurality of stringers.

18. The method of claim 17, wherein the step of securing a plurality’ of structural members together includes securing a plurality of bottom deckboards to a plurality of stringers.

19. The method of any of claims 14 to 18, wherein the composite pallet has two forklift openings.

20. The method of any of claims 14 to 19, wherein the composite pallet is formed to have a single-piece construction.

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