GB2489701A - Elastomer coated wooden pallet - Google Patents
Elastomer coated wooden pallet Download PDFInfo
- Publication number
- GB2489701A GB2489701A GB1105692.6A GB201105692A GB2489701A GB 2489701 A GB2489701 A GB 2489701A GB 201105692 A GB201105692 A GB 201105692A GB 2489701 A GB2489701 A GB 2489701A
- Authority
- GB
- United Kingdom
- Prior art keywords
- pallet
- coating
- elastomer
- wooden
- tag
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 229920001971 elastomer Polymers 0.000 title claims abstract description 56
- 239000000806 elastomer Substances 0.000 title claims abstract description 56
- 238000000576 coating method Methods 0.000 claims abstract description 64
- 239000011248 coating agent Substances 0.000 claims abstract description 63
- 238000000034 method Methods 0.000 claims abstract description 41
- 239000000654 additive Substances 0.000 claims abstract description 24
- 239000003063 flame retardant Substances 0.000 claims abstract description 17
- 238000001035 drying Methods 0.000 claims abstract description 14
- 229920003023 plastic Polymers 0.000 claims abstract description 13
- 239000004033 plastic Substances 0.000 claims abstract description 13
- 229920002635 polyurethane Polymers 0.000 claims abstract description 12
- 239000004814 polyurethane Substances 0.000 claims abstract description 12
- 239000003139 biocide Substances 0.000 claims abstract description 7
- 230000003115 biocidal effect Effects 0.000 claims abstract description 4
- 230000000855 fungicidal effect Effects 0.000 claims abstract description 4
- 239000000417 fungicide Substances 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims description 20
- 239000007921 spray Substances 0.000 claims description 16
- 238000003754 machining Methods 0.000 claims description 14
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 10
- 230000000996 additive effect Effects 0.000 claims description 8
- 238000005507 spraying Methods 0.000 claims description 8
- 239000002245 particle Substances 0.000 claims description 6
- 238000012545 processing Methods 0.000 claims description 6
- 238000004040 coloring Methods 0.000 claims description 5
- 239000000975 dye Substances 0.000 claims description 5
- 229920002396 Polyurea Polymers 0.000 claims description 4
- 239000004611 light stabiliser Substances 0.000 claims description 4
- 229920005862 polyol Polymers 0.000 claims description 4
- 150000003077 polyols Chemical class 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 239000000049 pigment Substances 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims description 3
- 239000004593 Epoxy Substances 0.000 claims description 2
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical group O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 claims description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 2
- 229920000608 Polyaspartic Polymers 0.000 claims description 2
- 229910052787 antimony Inorganic materials 0.000 claims description 2
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 claims description 2
- 239000000945 filler Substances 0.000 claims description 2
- 229910052736 halogen Inorganic materials 0.000 claims description 2
- 150000002367 halogens Chemical class 0.000 claims description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 2
- 239000011707 mineral Substances 0.000 claims description 2
- 239000011574 phosphorus Substances 0.000 claims description 2
- 229910052698 phosphorus Inorganic materials 0.000 claims description 2
- 239000003550 marker Substances 0.000 claims 3
- 235000014676 Phragmites communis Nutrition 0.000 claims 1
- 230000006378 damage Effects 0.000 abstract description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 5
- 239000000326 ultraviolet stabilizing agent Substances 0.000 abstract description 2
- 239000002023 wood Substances 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- 238000011109 contamination Methods 0.000 description 4
- 238000005303 weighing Methods 0.000 description 4
- 238000010348 incorporation Methods 0.000 description 3
- 230000003287 optical effect Effects 0.000 description 3
- 241000894006 Bacteria Species 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 239000012948 isocyanate Substances 0.000 description 2
- 150000002513 isocyanates Chemical class 0.000 description 2
- 230000035484 reaction time Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000002352 surface water Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 208000027418 Wounds and injury Diseases 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 239000004599 antimicrobial Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- FBYUNLMTXMFAQK-UHFFFAOYSA-N butyl dodecanoate Chemical compound CCCCCCCCCCCC(=O)OCCCC.CCCCCCCCCCCC(=O)OCCCC FBYUNLMTXMFAQK-UHFFFAOYSA-N 0.000 description 1
- 230000000981 bystander Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000011093 chipboard Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 239000000645 desinfectant Substances 0.000 description 1
- 239000003599 detergent Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000003814 drug Substances 0.000 description 1
- 229940079593 drug Drugs 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 208000014674 injury Diseases 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 238000013020 steam cleaning Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 150000003918 triazines Chemical class 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 230000004584 weight gain Effects 0.000 description 1
- 235000019786 weight gain Nutrition 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00258—Overall construction
- B65D2519/00313—Overall construction of the base surface
- B65D2519/00328—Overall construction of the base surface shape of the contact surface of the base
- B65D2519/00333—Overall construction of the base surface shape of the contact surface of the base contact surface having a stringer-like shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00258—Overall construction
- B65D2519/00313—Overall construction of the base surface
- B65D2519/00328—Overall construction of the base surface shape of the contact surface of the base
- B65D2519/00338—Overall construction of the base surface shape of the contact surface of the base contact surface having a discrete foot-like shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00258—Overall construction
- B65D2519/00368—Overall construction of the non-integral separating spacer
- B65D2519/00378—Overall construction of the non-integral separating spacer whereby at least one spacer is made of two or more pieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00736—Details
- B65D2519/00776—Accessories for manipulating the pallet
- B65D2519/00796—Guiding means for fork-lift
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00736—Details
- B65D2519/00825—Finishing of the external surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00736—Details
- B65D2519/00825—Finishing of the external surfaces
- B65D2519/0083—Anti-slip means
- B65D2519/00835—Integral
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
- B65D2519/00004—Details relating to pallets
- B65D2519/00736—Details
- B65D2519/0086—Protection against environmental hazards, e.g. humidity, bacteria, fire
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49888—Subsequently coating
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Pallets (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
The invention provides a method of monolithic continuous coating wooden pallets having a low moisture content with an elastomer coating, so as to provide pallets combining the advantageous qualities of wooden and plastic pallets. The pallets are light and inexpensive, tough and durable, water and damage resistant, fire retardant and non-slip. They can be produced by treating existing wooden pallets. The pallets may also have an RFID tag attached before coating for tracking the pallets and goods transported thereon. Additives such as biocide, fungicide and Ultra Violet stabilizers may be provided. The method may include drying the pallet in a kiln. The elastomer may be polyurethane, and may be sprayed onto the pallet.
Description
Pallets This invention relates to pallets for storing and transporting goods.
Pallets are generally fabricated from wooden batons and strips. Whilst they are relatively cheap to produce, wooden pallets havc the disadvantage that they are not water resistant and tend to absorb moisture which increases weight and decreases strength, and can damage the structure of the pallet through warping, shrinkage, mould and mildew growth and loosening of joints, for example by rusting and consequent weakening of the nails used to secure the wood together.
They are therefore unsuitable for use in some environments, and are difficult to clean.
Furthermore the porous nature of wood can lead to contamination with microbes, spores and bacteria, which can pose a risk to the goods contained therein or to those handling the pallets.
Wooden pallets also have variablefire-retardant qualities and can pose a fire risk.
In some circumstances plastic pallets are used, which have better water resistant qualities, but tend to pose a higher fire risk. Whilst plastic pallets may have fire-retardant added, this tends to worsen their mechanical properties. Furthermore, plastic pallets typically require a large amount of non-renewable expensive material and energy to produce, tending to make them more expensive to produce and less environmentally friendly.
The invention aims to reduce these problems by combining the benefits of wooden and plastic pallets.
According to one aspect of the invention there is provided a wooden pallet having a monolithic, continuous coating of an elastomer wherein the moisture content of the wooden pallet is less than 10% by weight of thc wooden pallet.
According to a further aspect of the invention there is provided a wooden pallet having a substantially monolithic, continuous coating of an elastomer wherein the coating comprises one or more additives selected from flame retardants, anti-slip additives and biocides.
The invention also provides a wooden pallet having an RFTD tag attached thereto, and a monolithic continuous coating of elastomer encapsulating the pallet and the tag.
The monolithic coating is such that it substantially encapsulates the pallet. The pallets of the invention may thus be completely enclosed in a coating of elastomer. By suitable selection of the coating elastomer the pallets may be provided with particular beneficial properties.
Furthermore, encapsulation of the pallet in the elastomer provides a waterproof coating and may ensure that water cannot be absorbed by the wood. This helps prevent rusting of the nails and thus improves the structural integrity of the pallet, and also means that the pallet has a fixed weight. This prevents weight gain that often occurs when wooden pallets are exposed to humidity or otherwise get wet and allows users to maximise loads and/or use less fuel to transport the pallets. The coated pallet according to the invention may weigh less than a conventional wooden pallet with an ambient moisture content. For example, a pallet dried according to the invention may have a minimum moisture content of at least 2%, sometimes at least 5%, and may have a weight of less than around 20kg, typically around 18kg, as compared to for example typically around 30kg for a pallet having ambient moisture levels (eg 40% moisture). The weight of the elastomcr coating including additives such as fire retardant is typically around 7kg, such that the coated pallet may have a fixed weight below 30kg; typically about 25kg.
The coating of elastomer may provide a non-slip surface which ensures safe handling, particularly on the tines of a forklift. This provides an advantage over many plastic pallets which may have a tendency to slip on the tines of a forklift, which can lead to loss of load and possible injury to bystanders. The non-slip surface may be enhanced by the incorporation of anti-slip additives into the elastomer.
The coating of the elastomer may provide high impact resistance and high tear strength improving the ability of the wooden pallet to withstand the potential damage of loading and handling operations. The coating of elastomer also prevents splinters from the wooden pallet and prevents nail protrusion providing a smooth supporting surface and improved handling.
Flame retardant properties which may meet the UL-94-VO standard may be provided by incorporation of suitable flame retardant additives into the elastomer.
Potential contamination of the wooden pallets may also be prevented by the coating of elastomer, Any microbes, spores and bacteria originally present may be killed or rendered inert in the drying process, and the coating provides a barrier to subsequent contaminants reaching the wood. The coating may readily be cleaned with water, detergent, disinfectant, pressure washing, steam cleaning etc. The elastomer may contain a biocide, e.g. a fungicide, to prevent contamination. The palicts arc thus suitable for use in the food and drug industries.
An identification tag, e.g. an REID tag or other remotely readable tag having a memory and unique identification, may be secured to the wooden pallet and covered by the coating of elastomcr thereby increasing the integrity of the labeled pallet. This enables the pallcts and any goods on them to be tracked and traced.
The coating of the elastomer may be coloured by the incorporation of dyes or pigments in the elastomer thereby providing for visual recognition of the pallets. The lifetime of the coloured coating may be improved by the presence of a ultraviolet light stabiliscr in the elastomcr, which typically otherwise tends to yellow' significantly over a relatively short time.
The coating of elastomer improves the lifetime of wooden pallets thereby providing economic advantages. Furthermore palicts according to the invention may use less plastics materials than conventional plastic pallets; for example approximately 3.5kg of elastomer compared with 25kg or 11kg for a lightweight plastic pallet. Due to the drying and machining process, the encapsulated wooden pallet may also have a total weight less than that of conventional wooden pallets.
The coating of clastomer generally has a thickness of from 1 to 5 mm, preferably 1 to 3mm, more preferably about 2mm. In principle, any elastomer which can readily be applied to a wooden pallet to provide a monolithic, continuous coating may be used. Suitable elastomers may be selected from polyurethane, polyurea, polyaspartics, epoxy, polyurethane-polyurea hybrids or any combination thereof. Elastomers formed rapidly from the reaction of two componcnts arc particularly preferred. The preferred elastomer is polyurethane.
Polyurethane is typically supplied as two components, an isocyanate and a polyether polyol or polyester polyol. The two components are mixed immediately prior to application, e.g. in the nozzle of a spray gun. The reaction between the components may be rapid and enhanced by the presence of a catalyst, e.g. an organotin compound, such as, dibutyl dilaurate. Preferably the components are selected so that the reaction time is less than 20 seconds, more preferably less than 5 seconds. A fast reaction time allows a first part of the wooden pallet to be spray and the immediately held or supported by the coated part to allow another part to be sprayed without damage to the coating of the first part. This allows a pallet to be completely coated in a short time.
A colouring additive may be added in the spray nozzle. Thus the coating colour may be changed by feeding different colouring into the spray head, according to requirement.
Polyurethane systems are well known and commercially available from many sources. A preferred isocyanate is diphenylmethane-4-4 -diisocyanate which is commercially available from Bayer under the trade name Desmodur 1327. A preferred polyol is commercially available from Bayer under the trade name Bayflex 89-624.
The selection of polyurethane and appropriate additives can have no volatile compounds and does not cause any EPA problems or Atex requirements allowing ease of processing.
The clastomer may contain additives to cnhance the properties of the coating. Suitable additives include flame retardants, anti-slip additives, biocides, colourant and ultraviolet stabilizers. The additives may conveniently be added to the polyol component of a polyurethane system.
Flame retardant additives are known and include hydrated fillers, halogen-containing materials, phosphorus-containing materials, antimony-containing materials and intumescent materials. A preferred flame retardant is aluminium trihydrate, e.g. commercially available from Ankerpoort NV under the trade name Portaflame. The flame retardant additives may be present in an amount of from 40 to 70%, preferably 50 to 60% by weight of the coating of clastomer.
The elastomer may comprise an anti-slip additive to improve the frictional characteristics of the surface of the coating. Suitable anti-slip additives arc selected from polymer particles, e.g. polymer beads having a particle size of about 250 micron and mineral particles, e.g. fine sand, silca-quartz particles.
The elastomer may comprise a biocidc, such as, a fungicide or anti-microbial agent, to prevent contamination. The elastomer may comprise a colouring agent, such as one or more dyes or pigments, to improve the appearance of the pallet and provide for visual recognition.
The elastomer may comprise an ultraviolet light stabilizer to prolong the life of the coloured coating. Suitable ultraviolet light stabilizers are known and include triazines and hindered amine light stabilizers (HALS).
According to a frirther aspect, the invention provides a method of producing a pallet as defined above comprising: drying a wooden pallet to a surface moisture content below about 10%, and applying an elastomer coating over the outside surface of the pallet.
Thus existing wooden pallets may be processed by this method to produce coated pallets according to the invention. This has the advantage that a customer may supply their own pallets to be coated, and may collect the pallets after the coating process has been applied. Thus a customer may purchase conventional pallets from existing suppliers for processing to obtain the advantages of the invention. Alternatively used or repaired pallets may also be treated according to the invention.
Preferably, the method comprises machining the outer surface of the pallet to predetermined tolerances before applying the elastomer coating. For example the surfaces of the pallet are machined to a substantially even finish. This facilitates the provision of a continuous and substantially even coating. Whilst it is known to paint or otherwise treat wooden pallets, it has been found that drying, machining and spray coating the wooden pallets with elastomer to substantially encapsulate the pallet according to the invention gives enhanced properties.
Before machining, the pallet may first be inspected, for example by a product recognition camera, to determine the size and type of pallet. The inspection may also determine whether the pallet is suitable for machining; for example, whether it has any discontinuities such as upstanding nails or fasteners or splintered timbers. Pallets which are determined not to be within dimensional tolerances set for the process may be rejected.
The method may also comprise applying an RFID tag to the surface of the pallet before applying the elastomer coating. Preferably, the RFTD tag is heat resistant and formed substantially of plastics material. The tag may be applied using a heat resistant attachment member, such as a staple, formed substantially of plastics material. The tag is conveniently applied to a surface of a central member of the pallet, for example on a side surface of a pallet member which faces inwardly, to prevent damage in use of the pallet.
The tag may be applied at the beginning of the process before drying the pallet. The pallet is preferably dried to a surface water content below about 10%, and preferably below about 8%, for example in a kiln. The kiln may include moisture and temperature sensors for measuring the surface water content of the pallet, and controlling the drying process. Although there may be some variation in the overall moisture content, it is found that measurement of the surface moisture gives a good measure of the overall moisture content as with a typical wooden pallet, wicking of moisture tends to equalize moisture levels throughout the material relatively quickly.
A more precise con-elation between surface moisture readings and overall moisture readings can be obtained for a particular pallet material and handling conditions by measuring total moisture content of test or calibration samples if desired.
The method preferably comprises using the RFID tag to store dimensions and/or other properties, such as a measure of drying time, weight or a measure of moisture content or tolerancesassociatedwiththepallet, eitherdirectlyonthetagorinadatabasereferencedbyan id on the tag. Preferably the pallet is machined by a router on the exposed or visible surfaces, and is then turned over to machine the remaining surfaces.
Coating the pallet preferably comprises spray coating. The elastomer material may be as defined above, and is preferably fast drying. Preferably a central member of the pallet is coated first, then the remainder of the surfaces exposed to the spray coater are coated whilst the coating on the central member cures. The pallet may then be gripped using the coated central member and manipulated in three dimensions to expose the remaining surfaces to the coater. Preferably the pallet is manipulated for example by a robot, and the spray head may also be robotically movable to produce an even spray, minimise overspray and to reduce spray time. This is important in allowing the process to have a high throughput rate.
Preferably, after spraying, the finished pallet is checked, preferably using a product recognition camera,andtheRFlDtagmayalsoberead, withthepalletthenbeingstoredforcollection according to information obtained from the tag.
The method may conveniently be automated, using powered conveyors and robots. The method may thus be used to process pallets quickly and in large quantifies. Thus the method provides a relatively inexpensive way of improving the qualities of wooden pallets.
According to yet another aspect, the invention provides a method of processing wooden pallets comprising: receiving a wooden pallet for coating; inspecting the pallet for suitability; applying an RF1D tag to a surface of the pallet containing information concerning the pallet; drying the pallet in a kiln; machining the surface of the pallet to predetermined tolerances excluding the area where the RFID tag is positioned; coating the pallet with elastomer material using a spray eoater; inspecting the pallet for finish; reading the RFID tag; and storing the pallet for collection according to information obtained from the tag.
In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings, in which; Figure 1 is a top view of a pallet suitable for processing in accordance with the invention; Figure 2 is an underneath perspective view of the pallet of Figure 1; Figures 3, 4 and 5 together show a flow diagram showing the components in a process for producing a pallet according to one embodiment the invention.
Referring to Figures I and 2, a wooden pallet 2 comprises three legs or stringers 3, 4, 5, which comprise parallel spaced wooden batons. To the upper surfaces of these are attached a plurality of thinner wooden strips 6 forming the top deck or load surface of the pallet 2. The strips 6 are placed close together and extend across the pallet perpendicular to the legs 4. For simplicity only the edge strips 6 are shown in Figure 2.
It will be appreciated that reference to the wood material of the pallet may include wooden products such as compressed wood or chipboard, etc. Referring also to Figures 3, 4, and 5, which show an example of a process according to the invention, wooden pallets for processing may be delivered to an unloading area 8. The pallets are conveyed by a first transfer conveyor 10, and are picked up one at a time by a robot on a load cell section for weighing each pallet The robot then offers each pallet to a tagging station 12 whereanRFlDtagisstapledtothepallet, fbrexampleusingaplasticstaple, on asideface 11 of a centre leg 4 of the pallet. The tag may include information such as a pallet identification code, ajob identification code, and other data relevant to the pallet.
The pallet is transferred from the tagging station to a further conveyor 14 and to an optical checking station 16. An optical check comprises inspecting the pallet with a product recognition camera to check the pallet size/type and that it is within dimensional tolerances for the process.
At this stage a failedpalletisrejectedand conveyedtoareject station 18 formanual checking.
A pallet which has passed the check is conveyed to a weighing station 20 where the weight of the pallet is logged. A further transfer conveyor 22 takes the pallet to a stacking station 23 where itisstackedbyarobotonagravityconveyor24. Thestackedpalletsrnaythenbetransferredby forklift to a kiln 26, via a storage area 28. The pallets are dried in the kiln according to requirement Moisture and temperature sensors are used to dry the pallets until they have a moisture content of about 8 to 10% by weight Thekilndriedpalletsarethenunloadedbyforkliftontoagravityrollerconveyor32vi aa holding area 30, to a second weighing station 34 which may comprise a load cell in the final section of the conveyor. The pallet is then transferred via a conveyor 36 to a machining station 38. A robot picks up each pallet and places four pallets on the bed of a muter where vacuum grippers hold them in place. The router reads the tag to identify the type of pallet and then machines the pallet on all faces to a set tolerance in accordance with the infbrrnation obtained.
The robot then turns over the pallets and the process is repeated on the other side. The router is programmed to ensure it does not machine the area where the tag is positioned. The pallets are transferred from the machining station via another conveyor 40.
A robot removes the pallets and places them individually vertically on a powered conveyor 42 with the underside facing spray bays of painting stations 44. The pallets travel along the conveyor and into holding station in front of each spray bay. A robot with a polyurethane spraying head sprays the centre leg first and then continues spraying the underside of the pallet.
A handling robot then picks up the pallet by gripping the coated centre foot and manipulates the pallet together with the moving spray head to minimize overspray and reduce spraying time.
When the pallet is completely coated it is placed face down on a powered conveyor 46. The final I.2m section is a gravity roller conveyor and mounted on a load cell. At an optical check station 48 a robot picks up the pallet, checks it for size/type and finish using a product recognition camera and reads the REID tag to identity the customer or pallet maker. If the pallet does not pass the check, it it sent to a reject station 50. Otherwise the pallet is transferred via a further weighing station 52 to a sorting station 54 where a robot stacks the pallet in correct place. The pallets ready for collection by the customer or pallet maker are transferred to a storage area 56, and thence to a delivery station 58 and loading area 60 as required.
As can be seen in the drawings, at each stage of the process, there may be a reader (eg 62) which reads the tag and sends data to a server (eg 64). In this way each pallet can be tracked through the process. Data such as the dimensions and tolerances and drying time for each pallet can also be collected. This data can be used by a computer control system for obtaining process information for controlling the process, for billing and also for quality control purposes.
For example data concerning rejection of pallets, or manual intervention required, for a batch of pallets associated with a customer may be used in deriving the charge to be made to that customer. Also, pallets can be graded according to the data concerning dimensional tolerances.
Claims (45)
- CLAIMS1. A wooden pallet having a substantially monolithic continuous coating of an elastomer wherein the moisture content of the wooden pallet is less than 10% by weight of the wooden pallet.
- 2. A wooden pallet having a monolithic, continuous coating of an elastomer wherein the coating comprises one or more additives selected from flame retardants, anti-slip additives and biocides.
- 3. A wooden pallet as claimed in Claim Il or Claim 2 wherein the coating of elastomer has a thickness of from 1 to 5 mm.
- 4. A wooden pallet as claimed in Claim 3 wherein the coating of elastomer has a thickness of from I to 3 mm.
- 5. A wooden pallet as claimed in Claim 4 wherein the coating of elastomer has a thickness of about 2 mm.
- 6. A wooden pallet as claimed in any preceding Claim wherein the coating of elastomer comprises a flame retardant additive.
- 7. A wooden pallet as claimed in Claim 6 wherein the flame retardant additive is selected from hydrated fillers, halogen-containing materials, phosphorus-containing materials, antimony-containing materials and intumescent materials.
- 8. A wooden pallet as claimed in Claim 7 wherein the flame retardant additive is aluminium trihydrate.
- 9. A wooden pallet as claimed in any one of Claims 6 to 8 wherein the flame retardant is present in an amount of from 40 to 70°/b by weight of the coating of elastomer.
- 10. A wooden pallet as claimed in Claim 9 wherein the flame retardant is present in an amount of from 50 to 60% by weight of the coating of elastomer.
- 11. A wooden pallet as claimed in any preceding Claim wherein the coating of elastomer comprises an anti-slip additive.
- 12. A wooden pallet as claimed in Claim ii wherein the anti-slip additive is selected from polymer particles and mineral particles.
- 13. A wooden pallet as claimed in any preceding Claim wherein the coating of elastomer comprises a bioeide.
- 14. A wooden pallet as claimed in Claim 13 wherein the biocide is a fungicide.
- 15. A wooden pallet as claimed in any preceding Claim wherein the coating of elastomer comprises a colouring agent.
- 16. A wooden pallet as claimed in Claim 15 wherein the colouring agent is selected from dyes and pigments.
- 17. A wooden pallet as claimed iii any preceding claim wherein the elastomer is selected from polyurethane, polyurea, polyaspartics, epoxy, polyurethane-polyurea hybrids or any combination thereof
- 18. A wooden pallet as claimed in Claim 17 wherein the elastomer is polyurethane.
- 19. A wooden pallet as claimed in Claim 18 wherein the polyurethane Is formed by reaction of diphenylmethane-4-4'-diisocyanate and a polyol.
- 20. A wooden pallet as claimed in Claim 18 wherein the polyurethane is formed by reaction of Bayflex 89-624 and Dcsmodur 1327.
- 21. A wooden pallet as claimed in any preceding Claim wherein the wooden pallet comprises and identity marker.
- 22. A wooden pallet as claimed in Claim 21 wherein the identity marker is beneath the coating of elastomer.
- 23. A wooden pallet as claimed in Claim 22 wherein the identity marker is an REID tag.
- 24. A wooden pallet as claimed in any preceding Claim wherein the elastomer comprises an ultraviolet light stabilizer.
- 25. A wooden pallet having an REiD tag attached thereto, and a monolithic continuous coating of elastomcr encapsulating the pallet and the tag.
- 26. A method of producing a pallet as claimed in any preceding claim comprising: drying a wooden pallet to a moisture content below about 10%, and applying an clastomer coating over the outside surface of the pallet.
- 27. A method as claimed in claim 26, comprising machining the outer surface of the pallet to within predetermined tolerances for coating before applying the elastomer coating.
- 28. A method as claimed in clan 26 or 27, comprising inspecting the pallet to determine whether the pallet is within predetermined dimensional tolerances for machining beforc machining the pallet.
- 29. A method as claimed in claim 26, 27 or 28, comprising applying an REID tag to an inner surface of the pallet before applying the elastomer coating.
- 30. A method as claimed in claim 29, in which the RFID tag is heat resistant.
- 31. A method as claimed in claim 30, in which the RHD tag is formed substantially of plastics material.
- 32. A method as claimed in claim 29, 30 or 31, in which the tag is applied using a heat resistant attachment member formed substantially of plastics material.
- 33. A method as claimed in any one of claims 29 to 32, comprising applying the tag to asurface of a central member of the pallet which extends perpendicular to a load surface of the pallet.
- 34. A method as claimed in any one of claims 26 to 33, comprising drying the pallet in a kiln.
- 35. A method as claimed in any one of claims 27 to 34, wherein machining the pallet comprises machining the surfaces of the pallet to substantially even surfaces using a router.
- 36. A method as claimed in any one of claims 26 to 35, in which coating the pallet comprises spray coating.
- 37. A method as claimed in claim 36, in which spray coating comprises coating a central member of the pallet, coating the remainder of the surfaces exposed to the spray coater, gripping the pallet using the coated central member, and manipulating the pallet to expose the remaining surfaces to the coater.
- 38. A method as claimed in claim 37, in which the pallet is manipulated by a robot, and the spray head is movable.
- 39. A method as claimed in any one of claims 26 to 38, comprising checking the finish of the coated pallet using a camera.
- 40. A method as claimed in any one of claims 29 to 39, comprising reading the RF'ID tag on the finished pallet, and storing the pallet for collection in a location according to information obtained from the tag.
- 41. A method of processing wooden pallets comprising: receiving a wooden pallet for coating; inspecting the pallet; applying an RFID tag to an inner surface of the pallet containing information concerning the pallet; drying the pallet in a kiln; machining the surfaces of the pallet to predetermined tolerances, excluding the area where the RFID tag is positioned; coating the pallet with elastomer material using a spray coater; inspecting the pallet for finish; reading the RFTD tag; and storing the pallet for collection according to information obtained from the tag.
- 42. A method as claimed in any preceding claim, in which applying the elastomer coating comprises mixing a two part elastomer, at least one of the parts comprising at least one of and preferably all of a fire retardant, an anti-slip, and a biocide additive, and comprising adding a dye to the mixed elastomer, the colour of the dye being selected according to predetermined criteria.
- 43. A wooden pallet having an REED tag attached thereto and a substantially continuous coating of elastomer encapsulating the pallet and the tag.
- 44. A pallet substantially as described herein, with reference to the accompanying drawings.
- 45. A method substantially as described herein, with reference to the accompanying drawings.
Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1105692.6A GB2489701A (en) | 2011-04-04 | 2011-04-04 | Elastomer coated wooden pallet |
CN201280022251.9A CN103562079A (en) | 2011-04-04 | 2012-04-04 | Pallets |
CA2832358A CA2832358A1 (en) | 2011-04-04 | 2012-04-04 | Pallets |
SG2013074711A SG194112A1 (en) | 2011-04-04 | 2012-04-04 | Pallets |
EP12713778.4A EP2694383A2 (en) | 2011-04-04 | 2012-04-04 | Pallets |
PCT/GB2012/050767 WO2012137006A2 (en) | 2011-04-04 | 2012-04-04 | Pallets |
KR1020137029124A KR20140043338A (en) | 2011-04-04 | 2012-04-04 | Pallets |
AU2012238438A AU2012238438A1 (en) | 2011-04-04 | 2012-04-04 | Pallets |
US14/009,716 US20140102338A1 (en) | 2011-04-04 | 2012-04-04 | Pallets |
ZA2013/08191A ZA201308191B (en) | 2011-04-04 | 2013-11-01 | Pallets |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1105692.6A GB2489701A (en) | 2011-04-04 | 2011-04-04 | Elastomer coated wooden pallet |
Publications (2)
Publication Number | Publication Date |
---|---|
GB201105692D0 GB201105692D0 (en) | 2011-05-18 |
GB2489701A true GB2489701A (en) | 2012-10-10 |
Family
ID=44071931
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB1105692.6A Withdrawn GB2489701A (en) | 2011-04-04 | 2011-04-04 | Elastomer coated wooden pallet |
Country Status (10)
Country | Link |
---|---|
US (1) | US20140102338A1 (en) |
EP (1) | EP2694383A2 (en) |
KR (1) | KR20140043338A (en) |
CN (1) | CN103562079A (en) |
AU (1) | AU2012238438A1 (en) |
CA (1) | CA2832358A1 (en) |
GB (1) | GB2489701A (en) |
SG (1) | SG194112A1 (en) |
WO (1) | WO2012137006A2 (en) |
ZA (1) | ZA201308191B (en) |
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GB2504763A (en) * | 2012-08-09 | 2014-02-12 | Palletworks Ltd | Surface treating a pallet core and spray coating with thermoplastic |
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US11826592B2 (en) | 2018-01-09 | 2023-11-28 | Mighty Fire Breaker Llc | Process of forming strategic chemical-type wildfire breaks on ground surfaces to proactively prevent fire ignition and flame spread, and reduce the production of smoke in the presence of a wild fire |
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US10846648B2 (en) * | 2019-01-03 | 2020-11-24 | Creative Asset Tracking Solutions, LLC | Systems and methods for tracking a wood pallet using an embedded tracking device |
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US11066210B1 (en) * | 2020-09-01 | 2021-07-20 | David Ankele | Nylon pallet |
US11911643B2 (en) | 2021-02-04 | 2024-02-27 | Mighty Fire Breaker Llc | Environmentally-clean fire inhibiting and extinguishing compositions and products for sorbing flammable liquids while inhibiting ignition and extinguishing fire |
US20230002090A1 (en) * | 2021-04-12 | 2023-01-05 | Sojo Industries, Inc. | Mobile automated modular variety and multi pack production line system and method |
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- 2012-04-04 WO PCT/GB2012/050767 patent/WO2012137006A2/en active Application Filing
- 2012-04-04 SG SG2013074711A patent/SG194112A1/en unknown
- 2012-04-04 EP EP12713778.4A patent/EP2694383A2/en not_active Withdrawn
- 2012-04-04 CA CA2832358A patent/CA2832358A1/en not_active Abandoned
- 2012-04-04 KR KR1020137029124A patent/KR20140043338A/en not_active Application Discontinuation
- 2012-04-04 US US14/009,716 patent/US20140102338A1/en not_active Abandoned
- 2012-04-04 AU AU2012238438A patent/AU2012238438A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
KR20140043338A (en) | 2014-04-09 |
US20140102338A1 (en) | 2014-04-17 |
CN103562079A (en) | 2014-02-05 |
AU2012238438A1 (en) | 2013-11-21 |
EP2694383A2 (en) | 2014-02-12 |
WO2012137006A3 (en) | 2013-01-03 |
CA2832358A1 (en) | 2012-10-11 |
GB201105692D0 (en) | 2011-05-18 |
WO2012137006A2 (en) | 2012-10-11 |
SG194112A1 (en) | 2013-11-29 |
ZA201308191B (en) | 2014-12-23 |
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