WO2002030768A2

WO2002030768A2 - Pallet

Info

Publication number: WO2002030768A2
Application number: PCT/IB2001/001871
Authority: WO
Inventors: Andries Willem Rousseau
Original assignee: Koen, Louis, Johannes; Bloem, Myndert, Petrus; Snyman, Wouter, Jacobus
Priority date: 2000-10-09
Filing date: 2001-10-09
Publication date: 2002-04-18
Also published as: WO2002030768A3; AU2001294080A1

Abstract

This invention relates to a pallet (10) which is made of rubber material. The invention also relates to a method of forming an article from a waste rubber source, the method including the steps of shredding the waste rubber source to obtain rubber shreds, combining the rubber shreds with a binder component, and forming a reinforced moulding of the article from the rubber shred/binder composition.

Description

PALLET

THIS INVENTION relates to a pallet. It also relates to a method of manufacturing a pallet and to a method of forming an article from a waste rubber source.

According to one aspect of the invention there is provided a pallet which is made of rubber material.

The pallet may be internally reinforced. The internal reinforcement may include at least one grid. The or each grid may be of welded steel tubing.

The rubber material may include a binder component and a rubberfiller component. The rubber material may include between about 50% to about 99% by mass rubber filler component and the balance binder component. More particularly, the rubber material may include about 91 ,4% by mass of rubber filler component.

The filler component may comprise rubber shreds. The rubber shreds may have a length of between about 1 mm and about 20 mm. The shreds may have a width of between about 1 mm and about 20 mm. In a preferred embodiment of the invention, the shreds have been sifted through a screen having apertures, the dimensions of which are about 10mm x 10 mm.

The filler component may comprise recycled rubber. The rubber may be recycled from used vehicle tyres.

The binder component may include a resin and a hardener. The resin may be a liquid epoxy resin. More particularly, the resin may be phenol, 4,4-[1 -methylethylidene]bis-, polymer with [chloromethylloxirane. The hardener may include a mixture of between about 25% and about 50% 3-aminomethyl-3, 5, 5- trimethylcyclohexylamine, between about 25% and about 50% benzyl alcohol and between about 2.5% and about 10% alkylphenol with non- hazardous additions. The resin may be combined with the hardener in a ratio of about 1.9 : 1.

The rubber material may include about 5.6% by mass resin and about 3% by mass hardener.

Instead, the binder component may be the reaction product of polyether and diphenylmethane 4,4-diisocyanate "MDI", which is available from National Urethane Industries under the trade mark ULTRATHANE 520-070.

The pallet may be generally square or rectangular in shape and include spaced upper and lower deckboards. Spacing blocks may extend between the upper and lower deckboards. The spacing blocks may extend between the upper and lower deckboards at each of four corners of the pallet, intermediate each of the four corners and at a centre of the pallet. The upper deckboard may be of lattice form, having twelve rectangular spaces defined between members of the deckboard.

The upper and lower deckboards may each be formed as a unitary moulding.

According to another aspect of the invention there is provided a method of manufacturing a pallet which includes the step of moulding at least part of t e pallet from rubber.

Preferably, the method includes moulding the at least part of the pallet from a waste rubber source, in particular used vehicle tyres.

The method may include moulding a reinforced upper deckboard and a reinforced lower deckboard and connecting the upper and lower deckboards together.

According to still another aspect of the invention there is provided a method of forming an article from a waste rubber source which method includes the steps of shredding the waste rubber source to obtain rubber shreds; combining the rubber shreds with a binder component; and forming a reinforced moulding of the article from the rubber shred/binder composition.

In a preferred embodiment of the invention, the article being formed is a pallet, the method then including moulding an upper deckboard and a lower deckboard and connecting the upper and lower deckboards together.

Forming the upper deckboard may include positioning reinforcing in a mould, introducing the rubber shred/binder composition into the mould and curing the rubber shred/binder composition.

Similarly, forming the lower deckboard may include positioning reinforcing in a mould, introducing the rubber shred/binder composition into the mould and curing the rubber shred/binder composition.

Connecting the upper and lower deckboards together may include connecting them to opposed sides of spacing blocks.

The reinforcing may be in the form of a grid. The reinforcing may be of welded steel tubing.

The binder component may be as hereinbefore described.

The rubber shreds may be combined with the binder component in a percentage of between about 50% by mass rubber and about 99% by mass rubber. Preferably, the rubber shreds are combined with the binder component in a percentage of about 91 .4% by mass rubber.

The method may include the steps of sifting the rubber shreds to separate off those shreds of desired dimension. The rubber shreds may be sifted through a screen having apertures whose dimensions are about 10 mm x 10mm.

When the waste rubber source is a used vehicle tyre, the method may include the step of extracting metallic material from the shreds prior to combining the rubber shreds with the binder component.

The metallic material may be magnetically extracted from the shreds.

The method may include washing and drying the shreds prior to combining them with the binder component. The shreds may be washed with a soap and water mixture.

The method may include compressing the rubbershreds and binder in the mould. Compressing the rubber shreds and binder may include applying a pressure thereto. The pressure may be about 39 200 Pa.

The method may include the step of curing the moulding. The curing process may include heating the moulding to about 50 degrees Celsius which serves to accelerate the curing process. The moulding will typically be heated while still in the mould and being subjected to pressure.

The method may include the step of coating the surface of the moulding with a sealant. The sealant may be in the form of an epoxy resin.

According to still another aspect of the invention there is provided a mould for a pallet as hereinbefore described. The invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings.

In the drawings, Figure 1 shows a perspective view of a pallet in accordance with the invention;

Figure 2 shows a sectional front view of the pallet of Figure 1 ; Figure 3 shows a plan view of an upper deckboard of pallet of Figure 1 ; and

Figure 4 shows a plεfn view of a lower deckboard of the pallet of Figure 1 .

In the drawings, reference numeral 10 refers generally to a pallet in accordance with the invention.

The pallet 10 is made of a reinforced rubber material 14 which includes a binder component and a rubber filler component. The rubber material 14 is prepared by combining about 91 ,4% by mass of rubber filler component with the balance binder component.

The pallet 10 is generally rectangular in outline in plan view and includes an upper deckboard 1 6 and a lower deckboard 18 spaced from and parallel with the' upper deckboard 1 6. Spacing blocks 20 extend between the upper and lower deckboards 16, 18 at each of the four corners of the pallet 10, intermediate each of the four corners and at the centre of the pallet 10. Typically, the spacing blocks 20 are manufactured from rubber material. As can best be seen in Figure 3 of the drawings the upper deckboard 1 6 is rectangular in outline in plan view, having a length of about 1 200 mm and a width of about 1 000 mm. The upper deckboard 16 is of a lattice form and includes twelve rectangular spaces 22 which are arranged in six rows of two spaces 22, the spaces 22 being defined between seven transverse members 24 and three longitudinal members 26 of the deckboard 16. Each rectangular space 22 is about 380 mm wide and about 100 mm in length and each longitudinal member 26 is about 84 mm wide. Each transverse member 24 is about 84 mm in width.

As can be seen in Figure 4 of the drawings, the lower deckboard 18 is rectangular in outline in plan view, having a length of about 1 200 mm and a width of about 1 000 mm. The lower deckboard 18 includes three transverse members 28 and three longitudinal members 30 between which four rectangular spaces 32 are defined. Each rectangular space 32 is of the dimensions 350 mm x 450 mm and each longitudinal member 30 is between about 80 and 100 mm wide. Each transverse member 28 is between about 80 and 100 mm in width.

It will be appreciated that the configuration of the upper and lower deckboards 16, 18 as well as the various dimensions of the pallet

10 can vary depending on the intended application of the pallet 10.

The upper deckboard 16 is formed by positioning a welded tubular steel reinforcing grid 12 in a mould and introducing the rubber material 14 into the mould. Similarly, the lower deckboard 18 is formed by positioning reinforcing in the form of a welded tubular steel grid 13 in a mould and introducing the rubber material 14 into the mould. Using steel tubing as a reinforcing has the advantage that an interior of the reinforcing is hollow which serves both to save material and reduce overall weight of the pallet 10. However, other suitable reinforcing may instead be used.

The filler component comprises rubber shreds. The rubber shreds are about 10mm x 10 mm, or smaller, in dimension. The rubber shreds are formed from rubber recycled from used vehicle tyres.

The rubber material 14 is prepared by shredding the used vehicle tyres to obtain the rubber shreds and combining (or mixing) the rubber shreds so-obtained with the binder component such that the resulting mixture comprises about 91 .4% by mass of rubber shreds with the balance being binder component. The preparation of the rubber material 14 includes the intermediate steps of magnetically extracting any metallic material which may be present amongst the shreds, and sifting the rubber shreds through a screen having apertures of about 10 mm x 10 mm in dimension so as to separate off those shreds of desired dimensions. The sifted shreds are then washed with a soap and water mixture and thereafter dried before being mixed with the binder component.

In one embodiment of the invention, the binder component includes a resin and a hardener. The resin may be liquid epoxy resin phenol, 4,4-[1 -methylethylidene]bis~, polymer with [chloromethylloxirane, which is available under the trademark DER 331 from The Dow Chemical Company. The hardener includes a mixture of between about 25% and about 50% 3-aminomethyl-3,5,5-trimethylcyclohexylamine, between about 25% and about 50% benzyl alcohol and between about 2.5% and about 10% alkylphenol with non-hazardous additions, such as that available under the trademark POLYPOX H043 from The Dow Chemical Company. The resin is combined with the hardener in a ratio of about 1 .9 : 1 . The rubber material 14 yielded by a combining/mixing of the rubber shreds and binder component includes about 5.6% by mass resin and about 3% by mass hardener.

In another embodiment of the invention, the binder component is the reaction product of polyether and diphenylmethane 4,4-diisocyanate "MDI", such as that available from National Urethane Industries under the trade mark ULTRATHANE 520-070.

Once introduced into the mould, the contents of the mould are subjected to a pressure of about 39 200 Pa while the resin cures. Curing of the resin is accelerated by the heating of the contents of the mould to about 50 degrees Celsius.

The spacing blpcks 20 can similarly be formed as mouldings of the rubber material with or without reinforcing.

The pallet 10 is formed by removing the upper and lower deckboards 16, 18 from their respective moulds and connecting them to opposed sides of the spacing blocks 20. The upper and lower deckboards 16, 18 are connected together by way of a sunken or countersunk screw 19 in the location of each spacing block 20, which screw 19 passes successively through the upper deckboard 16 and reinforcing grid 12 therein, the spacing block 20, and the lower deckboard 18 and reinforcing grid 13 therein. An adhesive agent, eg. glue, may furthermore be provided between the side of each spacing block 20 and the adjoining surface of the upper or lower deckboard 1 6, 18, as the case may be.

The Inventor believes that the pallet 10 in accordance with the invention will be suitable for exposure to the elements and will provide a water resistant platform for the moving, stacking or storing of goods. Furthermore, it will provide a long-life and biocidally treatable goods platform. Further, in view of the fact that the pallet is manufactured from used vehicle tyres, the pallet will serve to provide an effective purpose for which used tyres can be recycled with substantial ecological and environmental benefits.

Claims

CLAIMS:

1 . A pallet which is made of rubber material.

2. A pallet as claimed in Claim 1 , which is internally reinforced.

3. A pallet as claimed in Claim 2, in which the internal reinforcement includes at least one grid.

4. A pallet as claimed in Claim 3, in which the or each grid is of steel tubing.

5. A pallet as claimed in any one of the preceding claims, in which the rubber material includes a binder component and a rubber filler component.

6. A pallet as claimed in Claim 5, in which the rubber material includes between 50% and 99% by mass rubber filler component and the balance binder component.

7. A pallet as claimed in Claim 6, in which the rubber material includes 91 ,4% by mass of rubber filler component.

8. A pallet as claimed in any one of Claims 5 to 7, inclusive, in which the filler component comprises rubber shreds.

9. A pallet as claimed in Claim 8, in which the rubber shreds have a length of between 1 mm and 20 mm.

10. A pallet as claimed in Claim 8 or Claim 9, in which the shreds have a width of between 1 mm and 20 mm.

1 1 . A pallet as claimed in Claim 9 or Claim 10, in which the shreds have been sifted through a screen having apertures the dimensions of which are 10mm x 10 mm.

12. A pallet as claimed in any one of Claims 5 to 1 1 , inclusive, in which the filler component comprises recycled rubber.

13. A pallet as cl imed in Claim 12, in which the rubber is recycled from used vehicle tyres.

14. A pallet as claimed in any one of Claims 5 to 13, inclusive, in which the binder component is the reaction product of polyether and diphenylmethane 4,4-diisocyanate "MDI".

1 5. A pallet as claimed in any of Claims 5 to 13, inclusive, in which the binder component includes a resin and a hardener.

16. A pallet as claimed in Claim 15, in which the resin is a liquid epoxy resin.

17. A pallet as claimed in Claim 16, in which the resin is phenol, 4,4-[1 -methylethylidene]bis-, polymer with [chloromethyl]oxirane.

18. A pallet as claimed in any one of Claims 1 5 to 17, inclusive, in which the hardener includes a mixture of between 25% and 50% 3- aminomethyl-3,5,5-trimethylcyclohexylamine, between 25% and 50% benzyl alcohol and between 2.5% and 10% alkylphenol with non- hazardous additions.

1 9. A pallet as claimed in any one of Claims 1 5 to 18, inclusive, in which the resin is combined with the hardener in a ratio of 1 .9 : 1 .

20. A pallet as claimed in any one of Claims 15 to 19, inclusive, in which the rubber mater^'ral includes 5.6% by mass resin and 3% by mass hardener.

21 . A pallet as claimed in any one of the preceding claims, which is generally square or rectangular in shape and includes spaced upper and lower deckboards.

22. A pallet as claimed in Claim 21 , in which spacing blocks extend between the upper and lower deckboards.

23. A pallet as claimed in Claim 22, in which the spacing blocks extend between the upper and lower deckboards at each of four corners of the pallet, intermediate each of the four corners and at a centre of the pallet.

24. A pallet as claimed in any one of Claims 21 to 23, inclusive, in which the upper deckboard is of lattice form, having a plurality of rectangular spaces defined between members of the deckboard.

25. A pallet as claimed in any one of Claims 21 to 24, inclusive, in which the upper and lower deckboards are each formed as a unitary moulding.

26. A method of manufacturing a pallet, which method includes the step of moulding at least part of the pallet from rubber.

27. A method as claimed in Claim 26, which includes moulding the at least part of the pallet from a waste rubber source.

28. A method as claimed in Claim 27, in which the waste rubber source is used vehicle tyres.

29. A method as claimed in any one of Claims 26 to 28, inclusive, which method includes moulding a reinforced upper deckboard and a reinforced lower deckboard and connecting the upper and lower deckboards together.

30. A method of forming an article from a waste rubber source, which method includes the steps of shredding the waste rubber source to obtain rubber shreds; combining the rubber shreds with a binder component; and forming a reinforced moulding of the article from the rubber shred/binder composition.

31 . A method as claimed in Claim 30, in which the article being formed is a pallet, the method including moulding an upper deckboard and a lower deckboard and connecting the upper and lower deckboards together.

32. A method as claimed in Claim 31 , in which connecting the upper and lower deckboards together includes connecting them to opposed sides of spacing blocks.

33. A method as claimed in Claim 31 or Claim 32, in which moulding the upper deckboard includes positioning reinforcing in a mould, introducing the rubber shred/binder composition into the mould and curing the rubber shred/binder composition.

34. A method as claimed in any one of Claims 31 to 33, inclusive, in which moulding^'the lower deckboard includes positioning reinforcing in a mould, introducing the rubber shred/binder composition into the mould and curing the rubber shred/binder composition.

35. A method as claimed in Claim 33 or Claim 34, in which the reinforcing is in the form of a grid.

36. A method as claimed in any one of Claims 33 to 35, inclusive, in which the reinforcing is of steel tubing.

37. A method as,; claimed in any one of Claims 30 to 36, inclusive, in which the binder component is the reaction product of polyether and diphenylmethane 4,4-diisocyanate "MDI".

38. A method as claimed in any one of Claims 30 to 36, inclusive, in which the binder component includes a resin and a hardener.

39. A method as claimed in Claim 38, in which the resin is a liquid epoxy resin.

40. A method as claimed in Claim 39, in which the resin is phenol, 4,4-[1 -methylethylidene]bis-, polymer with [chloromethyljoxirane.

41 . A method as claimed in any one of Claims 38 to 40, inclusive, in which the hardener includes a mixture of between 25% and 50% 3-aminomethyl-3,5,5-trimethylcyclohexylamine, between 25% and 50% benzyl alcohol and between 2.5% and 10% alkylphenol with non- hazardous additions.

42. A method as claimed in any one of Claims 38 to 41 , inclusive, in which the resin is combined with the hardener in a ratio of 1 ,9 : 1 .

43. A method as claimed in any one of Claims 38 to 42, inclusive, in which the rubber material includes 5,6% by mass resin and

3% by mass hardener.

44. A method as claimed in any one of Claims 30 to 43, inclusive, in which the rubber shreds are combined with the binder component in a percentage, of between 50% by mass rubber and 99% by mass rubber.

45. A method as claimed in Claim 44, in which the rubber shreds are combined with the binder component in a percentage of 91 .4% by mass rubber.

46. A method as claimed in any one of Claims 30 to 45, inclusive, which includes the steps of sifting the rubber shreds to separate off those shreds of desired dimension.

47. A method as claimed in Claim 46, in which the rubber shreds are sifted through a screen having apertures whose dimensions are 10 mm x 10mm.

48. A method as claimed in any one of Claims 30 to 47, inclusive, in which the waste rubber source is a used vehicle tyre, the method including the step q,f extracting metallic material from the rubber shreds prior to combining the rubber shreds with the binder component.

49. i A method as claimed in Claim 48, in which the metallic material is magnetically extracted from the rubber shreds.

50. A method as claimed in any one of Claims 30 to 49, inclusive, which includes washing and drying the rubber shreds prior to combining them with the binder component.

51 . A method as claimed in Claim 50, in which the shreds are washed with a soap and water mixture.

52. A method as/ claimed in any one of Claims 30 to 51 , inclusive, which includes compressing the rubber shreds and binder in a mould.

53. A method as claimed in Claim 52, in which compressing the rubber shreds and binder includes applying a pressure thereto.

54. A method as claimed in Claim 53, in which the pressure is

39 200 Pa.

55. A method as claimed in any one of Claims 30 to 54, inclusive, which includes the step of curing the moulding.

56. A method as claimed in Claim 55, in which curing the moulding includes heating the moulding to 50 degrees Celsius to accelerate the curing process.

57. A method as claimed in any one of Claims 30 to 56, inclusive, which includes the step of coating the surface of the moulding with a sealant.

58. A method as claimed in Claim 57, in which the sealant is in the form of an epoxy resin.,

59. A mould for a pallet as claimed in any one of Claims 1 to 25, inclusive.

60. A pallet as claimed in Claim 1 , substantially as herein described and illustrated.

61 . A method as claimed in Claim 26, substantially as herein described and illustrated.

62. A method as claimed in Claim 30, substantially as herein described and illustrated.

63. A mould as claimed in Claim 59, substantially as herein described and illustrated.

4. A new pallet, a new method or a new mould, substantially herein described.