EP4724354A1

EP4724354A1 - Extruded plastic pallet

Info

Publication number: EP4724354A1
Application number: EP25827407.5A
Authority: EP
Inventors: Kunnamkumarath VENUGOPALAN
Original assignee: Al Haya Waste Treatment Factory
Current assignee: Al Haya Waste Treatment Factory
Priority date: 2025-03-06
Filing date: 2025-07-23
Publication date: 2026-04-15
Also published as: WO2026005632A1

Abstract

The conventional wooden pallets are making de-forestation, lower sustainability, prone to absorb bacteria,chemical contamination & splinters and damage. The wooden pallet required ISPM no.15 (International Standard for Phytosanitary Measures no.15 for the regulation of food packaging material. The roto-molded plastic pallets are cannot be easily repaired when damaged. Plastic pallets are more expensive than wooden pallets. Plastic pallets contribute to increase the carbon footprint. Etruded Plastic Sand pallets are durable, repairable, exempted from ISPM no.15. The present invention consists of two elements stiffener(2) and rib(3) gluing together to make a pallet. Etruded pallet do not required any mechanical fastners.

Description

Title of Invention : EXTRUDED PLASTIC PALLET (1)

[0001] he present invention Extruded Plastic pallet (1) consists of only two elements stiffener(2) and rib (3) joined by glue without mechanical fastners to make a pallet used for handling, storing, and moving material packages.

Technical Field

[0002] The process steps of making Extruded plastic pallet(1) of this invention is described below ).

[0003] Prepare a mixture(4) with the following components Plastic (5) , sand (6) and color (7) as per the ratio of figure 4 table(1).

[0004] Heat the mixture by the help of an extruder (28), maintaining a temperature 270 to 320 celsious and pour the molten mixture(4) ) into the mould cavity (30) and press down the upper part of mould press (31) to strengthen the stiffner (2) or rib (3).

[0005] Allow cooling down for 60 to 120 seconds, then lift the upper part of press (31) . Take out the moulded part stiffener(2) .

[0006] Repeat the same process to second mould for making the rib (3).

[0007] If sufficient number of Stiffener (2) & ribs (3) are made, then assemble it as per the figure 1 by glueing the stiffener (2) and ribs(3) together for required size & shape(rectangular or square).

Background Art

[0008] The standard pallets are useful for maneuvering the materials by inserting their forks into the channels provided by the pallet.

[0009] The wooden pallets are simple but leads to de-forestation and the requirement of ISPM no.15.

[0010] The Roto-molded plastic pallets impact with higher carbon footprint & non-repairable.

[0011] A wide variety of moulded pallets are on the market, manufactured by virgin or recycled plastic granules and with fiber adhesive types.

[0012] The plastic Pallets making will generate higher carbon footprints, higher in cost and the non-repairable leads to inventing an easier manufacturing of durable, low cost, low carbon footprint circular economy model pallet). Summary of Invention

[0013] The present invention fills the need for a low cost, repairable, ISPMno.15 exempted pallet and a method for manufacturing the pallet (1).

[0014] The present invention consists multiple number of only two elements (stiffener(2) & rib(3) to make a pallet.

[0015] The present invention provides a better industrial applicability than the prior art published patent US 2008/0110377 A1 (stevens) which contains three elements(referring the patent figure one lower part (914), one upper part (910) and a separate middle part square block(912) to make the pallet.

[0016] The pallet stiffener & ribs were made by Extrusions load press which differs than making by Rotomold as in FR3149877A3 (Flexipal As) S US 2008/0110377 A1 (stevens) .

[0017] The present invention provides better industrial applicability than the prior art patent published US 2008/0110377 A1 (stevens), making a pallet as two identical halves fastened together one upon inversely.

[0018] The mouldable mixture is a blend of 26% to 40 wt % of plastic and 60 to 74 wt% of sand

[0019] The mouldable mixture shall have 0.5 wt % color additive to get preferred color.

[0020] The identical ratio of plastic-sand mixture (4) .where as the sand (6) & plastic (5) percentage shall be varied; the maximum plastic shall be 90 wt % and minimum plastic should be 26 wt %; similarly the Maximum Sand shall be 74 wt % and minimum 10 wt%.

[0021] The above mixture (4) is extruded in an extruder, heating upto 278 C to 320 C to make a mouldable mixture.

Technical Problem

[0022] The published patent US 2008/0110377 A1 (stevens) which contains three elements(referring the patent figure one lower part (914), one upper part (910) and a separate middle part square block(912) to make the pallet fastened together with removable means.

[0023] The patent FR3149877A3 (Flexipal As) also have three elements upper part, lower part and a hollow square block connecteing upper & lower parts.

[0024] The present invention ave onle two elements stiffener(2) and rib(3) to make a plastic-sand pallet at various size & shapes fastened by glue. [0025] Earleir models of pallets requires more Storage space, Logistics & transportation required more space because only assembled pallet shall be transportable; whereas the present invention the elements shall be packed in a cartoon box and transported to the site and ashall assemble at site by glueing.

Solution to Problem

[0026] A new design developed, with only two elements to make an extruded pallet(1).

[0027] The new manufacturing method extrusion & load press replaces rotomolding.

[0028] The stiffener(2) and Ribs(3) are joined together with glue for assembling which allows unassembles parts transportation and reduces storage space.

[0029] The special design helps to to make strong pallet than other types in the market.

Advantageous Effects of Invention

[0030] Extruded pallets are durable, repairable, exempted from ISPM no.15.

[0031] Etruded pallets shall packed by indivual elements in a cartoon box of 1.3 *0.5 meter, and shall be assembled at site location; which helps to reduce space for logistics & transportation

Increase usage of recycled plastic and recycled sand from construction demolition waste recycling, Reduces carbon foot print impact.

Brief Description of Drawings

[0032] The present invention shall be easily understood by the following descriptions & accompanied drawings.

Fig.1

[0033] [fig.1 ] illustrates a view of an Extruded pallet (1) assembled in accordance with the present invention.

Fig.2

[0034] [fig.2] illustrates the stiffener (2) member of the plastic-sand pallet (l)llustrates the work flow in flow chart.

Fig.3

[0035] [fig.3] illustrates the plurality of ribs (3) used in top & bottom of Stiffener to make Extruded pallet (1 ) [0036] [fig.4] Table-1 illustrates the various compositions of plastic-sand mixture (4) for making Extruded pallet (1 )

Fig.5

[0037] [fig.5] illustrates the plastic waste of high-density polyethylene crushed (5) for making the composition of plastic-sand mixture (4) for the Extruded pallet (1)

Fig.6

[0038] [fig.6] illustrates the sand(6) or recovered sand from construction demolition waste for making composition of plastic-sand mixture (4) for Extruded pallet (1)

Fig.7

[0039] [fig.7] illustrates the basic extruder (28) for heating blending of the mixture (4).

Fig.8

[0040] [fig.8] illustrates the basic press (32) & dye mould cavity(30) to make the stiffeners(2) & ribs(3).

Description of Embodiments

[0041] In the following the details of the manufacturing of a pallet for present invention has been given.

Figure 1 Assembled view of Plastic-sand Pallet (1)

[0042] Figure 1 illustrates the assembled view of an assembled Extruded pallet of this invention. There are only two types of members used to make this type of pallet; one is stiffener (2) and another is ribs (3).

[0043] The pallet have a plurality ribs (3) preferably six numbers at top of stiffener (2) and four numbers at the bottom of stiffener (2). The ribs are made from plastic-sand mixture (4) expressed in this invention

[0044] The Extruded pallet(1) have plurality stiffeners (2) preferably four numbers at the middle of the pallet, which helps to spread load evenly to all ribs (3). The load-bearing stiffeners (2) are made out of plastic-sand mixture(4) expressed in this invention.

[0045] The stiffeners (2) have been designed to have a minimum 55 mm leg height, which will be raised by bottom rib(3) to have a maximum 74 mm space to accommodate various types of lifting mechanism like forklift or pallet trolly etc.

[0046] The ribs (3) were joined with glue to the stiffener (3) for assembling the pallet (1). Fig 2 Stiffener (2)

[0047] The figure 2 illustrate the details of stiffener (2) used to make plastic-sand pallet (1).The stiffener (2) is made of the plastic-sand mixture (4) expressed in this invention. The stiffener (2) is a moulded one piece and pressed with 200 ton press (32). The extruded plastic-sand mixture (4) will pour into the mould cavity and press with a 200 ton press(32) for strengthening the stiffener(2).

[0048] The stiffener is designed with a channel in the center, the channel have connected with internal ridges to strengthen the moulded stiffener (2)

[0049] The height of the stiffener (2) maximum is 100 mm, and width will be 30 mm and length will 1200 mm. The length & width may vary according to the size of pallet (1) requirement, where as the height will be always same as 100mm. The stiffener (2) have a notch at a height of 55 mm, which will raise to 74 mm by assembling the bottom ribs (3), this notch will be useful to insert a forklift forks two ways or pallet jack

Fig.3 Ribs(3)

[0050] The figure 3 illustrates the Ribs (3) manufactured from the plastic-sand mixture (4) expressed in this invention

[0051] The Ribs (3) are designed identical with a width of 70 mm and height or thickness 19mm and the length will be 1200mm. The width & thickness will be same for all pallets whether the length will be varied as per pallet (1) size requirement.

[0052] The Ribs (3) are made with three elevated surface each have 14 mm width and 19 mm thickness, and two channels each have 14mm width and 3 mm depth, from the elevated surface of top & bottom. This design will give additional strength to the ribs (3) for bearing more loads.

Figure 4, Table 1. Formula for plastic-sand mixture (4) for Extruded pallet (1)

[0053] The above table is an identical ratio of plastic-sand mixture (4), whereas the plastic(5) , sand (6) percentage shall be varied; the maximum plastic(5) shall be 90 wt % and minimum plastic(5) should be 26 wt %; similarly the Maximum Sand (6) shall be 74 wt % and minimum sand (6) will be 10 wt%.

[0054] The color (7) shall be 0.25% by wt, and any color shall be used, preferably green.

Fig.5 Plastic (5)

[0055] The post consumer HDPE plastic waste (5) have to be crushed to 5 to 8 mm size for making the mixture (4)

[0056] The PET,LDPE,ABS plastic waste also shall be used y crushing into 5 mm size.

Fig.6 Sand (6)

[0057] The sand (6) or recovered sand from construction demolition waste shall be used to make the mixture(4), and the sand (6) minimum 0.15mm to maximum sizel .5 mm, preferably 0.6mm have to be used. Fig.7 Extruder (28)

[0058] The extruder for heating & blending of the miture (4) simple drawing given.

[0059] The extruder rotates by a motor and the miiture powder form will insert in it, and heat it by the heating coils of extruder

Fig.8 Press (32)

[0060] A conventional hydraulic press is used to compress the molten mixture for strengthening the stiffner(2) and ribs(3).

Industrial Applicability

[0061] The present invention Etruded pallet(1) shall be applied to manufacture large scale.

[0062] Due to the uniqness and easy to assemple at site, the members stiffeners(2) and Ribs(3) of Extruded pallet (1) shall pack in a carboard box and transport to any part of the world.

[0063] It is required less space to store in a wear house or shipping container.

[0064] The inventor along with applicant already started manufacturing of the Extruded pallet at applicant’s factory

Reference Signs List

[0065] The first pallet patent is from 1925 by a gentleman called Howard. T. Hallowell who named it a “lift truck platform”.

[0066] There after many modifications & inventions taken place across the world and those some are documents listed in the citation list

Reference to Deposited Biological Material

[0067] There is no biological materials involved in this invention, so the biological reference is not applicable .

Sequence Listing Free Text

[0068] Since there is no biological materials used in this invention, then the sequence listing is not applicable to this pattent application .

Citation List

[0069] Citation List follows: [0070] FR3149877A3 (Flexipal As) US 2178646A - pallet

[0071] US 2008/0110377 A1 (stevens)

[0072] US2372055A1945-03-20Pallet

Patent Literature

[0073] The patent literature is not availtable for the pallet manufacturing.

Non Patent Literature

[0074] The non patent literature shall be cross verified with the citation list prior patents for wooden pallet and plastic pallet, i

Claims

[Claim 1] An Extruded Pallet (1) , comprising multiple number of only two elements stiffener (2) and Rib (3) assembled by glueing the together to make various size & square or rectangular shapes.

[Claim 2] According to claim 1, The two elements stiffner(2) and Rib (3) of the pallet is made by extrusion(28) & load press (32).

[Claim 3] The Extruded pallet (1) according to claim 1 .wherein it is made from a combination of only two members Stiffener (2) and Ribs (3).

[Claim 4] The Extruded pallet (1) according to any of proceeding claims, wherein it is joined by glueing .

[Claim 5] The Extruded pallet (1) according to any of proceeding claims, wherein it is made from various sizes (lengths width) of the stiffeners (2) and various sizes (length S width) of ribs (3) for suitability of various sizes of the pallet( 1 ) used worldwide.

[Claim 6] The Extruded pallet (1) according to claim 1 , wherein it is made by special design of stiffener (2) as shown in fig 2 and Rib (3) as shown in fig 4 to get more strengthen of the elements stiffener(2) and rib(3).