Pultrusion pallet

Abstract

A pallet made of pultrusion preferably includes a main deck and cross-members having unidirectional fibers and glass or fiber mat therein. The main deck and cross-members are assembled by many various means, including a unitary design or attached through the use of structural adhesives, brackets, rivets, and the like. A pair of fastening devices are provided to secure the goods to the pallet.

1 . A pultruded pallet comprising: 
 a substantially planar deck having a plurality of parallel structural supporting cross-members extending substantially perpendicular therefrom, the deck and extending cross-members being integrally formed from a monolithic piece of pultruded material.    
   
   
       2 . A pallet according to  claim 1 , wherein the pultruded material comprises a fiber reinforced thermosetting resin including at least one of a glass mat, fiber mat, and woven roving material.  
   
   
       3 . A pallet according to  claim 2 , wherein the thermosetting resin comprises a mixture of about 40 to about 60% by weight of continuous uni-directional fibers and from about 10 to about 30% by weight of veil mat or woven roving material.  
   
   
       4 . A pallet according to  claim 1 , wherein the deck has an average thickness of between about 3 and about 5 millimeters.  
   
   
       5 . A pallet according to  claim 1 , wherein the deck comprises a plurality of spaced apart apertures.  
   
   
       6 . A pallet according to  claim 1 , wherein the plurality of extending cross-members comprises a center member and two side members.  
   
   
       7 . A pallet according to  claim 1 , further comprising at least one pultruded end cap mechanically fastened to the deck and disposed-perpendicular to the cross members.  
   
   
       8 . A pallet according to  claim 7 , wherein the at least one pultruded end cap comprises a substantially “C” shaped cross-section.  
   
   
       9 . A pallet according to  claim 1 , further comprising a pair of elongated fastening devices configured to secure goods placed on the deck.  
   
   
       10 . A pallet according to  claim 9 , wherein the fastening devices comprise first and second pultruded extension brackets configured to cooperate with one another to provide a variable length.  
   
   
       11 . A pallet according to  claim 10 , wherein the extension brackets are telescopically coupled to one another for coordinated slidable movement to provide a variable length.  
   
   
       12 . A pallet according to  claim 9 , wherein the fastening devices further comprise at least one protruding retaining member.  
   
   
       13 . A pallet according to  claim 9 , wherein the fastening devices further comprise at least one groove or recess formed therein.  
   
   
       14 . A pallet according to  claim 9 , further comprising at least one retaining strap configured to secure the fastening devices to goods placed on the pallet.  
   
   
       15 . A system for shipping goods, the system comprising: 
 a pallet comprising a pultruded main deck and a plurality of pultruded structural supporting cross-members;    a pair of pultruded fastening devices configured to secure goods placed on the pallet; and    at least one retaining strap,    wherein the deck, cross-members, and fastening members comprise a fiber reinforced thermosetting resin and the at least one retaining strap is configured to secure the fastening devices to the goods.    
   
   
       16 . A system according to  claim 15 , wherein the main deck and cross-members are integrally formed from a monolithic piece of pultruded material.  
   
   
       17 . A system according to  claim 15 , wherein the main deck and cross-members are separately pultruded and mechanically fastened having a rectangular frame.  
   
   
       18 . A system according to  claim 15 , further comprising a second retaining strap configured to secure the fastening devices to the pallet.  
   
   
       19 . A system according to  claim 18 , wherein at least one of the supporting cross-members comprises a tubular cross-section the second retaining strap is wrapped around the fastening devices and passes through the cross-member.  
   
   
       20 . A system according to  claim 15 , wherein the thermosetting resin comprises a mixture of about 40 to about 60% by weight of continuous uni-directional fibers and from about 10 to about 30% by weight of veil mat or woven roving material.  
   
   
       21 . A system according to  claim 15 , wherein the pallet comprises at least one pultruded end cap mechanically fastened to the main deck and disposed perpendicular to the cross members.  
   
   
       22 . A system according to  claim 15 , wherein each fastening member comprises two extension brackets telescopically coupled to one another for coordinated slidable movement to provide a variable length.  
   
   
       23 . A system according to  claim 15 , wherein the fastening devices further comprise at least one protruding retaining member or recess configured to secure the at least one retaining strap.  
   
   
       24 . A system according to  claim 15 , wherein the goods comprise sheets of glass.  
   
   
       25 . A method of making a pultruded pallet, comprising: 
 preparing and blending a resin mixture;    aligning reinforcement materials through a guide plate into a predetermined formation and saturating the reinforcement materials with the resin mixture;    passing the saturated reinforcement materials through a frame die and pultruding an elongated monolithic component; and    cutting the monolithic component to a desired size.    
   
   
       26 . A method according to  claim 25 , further comprising: 
 pultruding an elongated end cap component;    cutting the end cap component to a desired size; and    mechanically fastening the end cap to the monolithic pallet component.    
   
   
       27 . A method according to  claim 25 , wherein the monolithic component comprises a deck having a plurality of parallel structural supporting cross-members extending substantially perpendicular therefrom.