Pallet with composite components

Abstract

A pallet having a first deck,a second deck, and a plurality of composite block members securing the first and second decks together to form a pallet. The composite block members and lead boards of the first and/or second deck comprise a composite material including about 50%-55% by weight of juniper or conifer particles and about 45%-50% by weight of a plastic component including a major portion of polyethylene.

1 . A pallet comprising: 
 a first deck;    a second deck; and    a plurality of block members connecting the first and second decks together to form a pallet, the block members comprising a composite material including at least about 20% by weight of natural material particles and at least about 20% by weight of plastic material particles.    
   
   
       2 . The pallet according to  claim 1 , wherein the natural material particles comprise ground particles of whole trees selected from the group consisting of junipers and conifers, the whole trees including root particles, trunk particles, branch particles, needle particles, wood particles, and mixtures thereof.  
   
   
       3 . The pallet according to  claim 2 , wherein the natural material particles comprise at least one wood selected from the group consisting of: Apache Plume; Ash, single-leaf; Bitterbrush; Cliffrose; Fendlerbush; Juniper, one-seed; Juniper, rocky mountain; Mahogany, curl-leaf; Mahogany, mountain; Mock Orange; Ponderosa Pine; Mormon Tea; and mixtures thereof.  
   
   
       4 . The pallet according to  claim 1 , wherein the plastic material particles comprise at least one material selected from the group consisting of polypropylene, polyethylene, polyurethane, polyvinylchloride, poly(ethylene terephthalate), nylon, and mixtures thereof.  
   
   
       5 . The pallet according to  claim 1 , wherein at least one of the first and second decks comprises a substantially rectangular frame having a plurality of longitudinally and laterally extending cross members, further wherein at least one of the plurality of cross members comprises a composite material comprising at least about 20% by weight of natural material particles ground from whole trees and at least about 20% by weight of plastic material particles.  
   
   
       6 . The pallet according to  claim 5 , wherein the at least one cross member comprises a lead board.  
   
   
       7 . The pallet according to  claim 1 , wherein the block members comprise at least about 50% by weight of natural material particles.  
   
   
       8 . The pallet according to  claim 1 , wherein the block members comprise at least about 45% by weight of plastic material particles.  
   
   
       9 . The pallet according to  claim 8 , wherein the block members comprise at least about 45% by weight of a thermoplastic component comprising a major portion of polyethylene.  
   
   
       10 . The pallet according to  claim 1 , wherein the block members further comprise at least one filler selected from the group consisting of colorants, UV protectors, flame and fire retardants, lubricants, soaps, polymer initiators, coupling agents, and mixtures thereof.  
   
   
       11 . The pallet according to  claim 1 , wherein the block members have an average water absorption of less than about  15 % by weight.  
   
   
       12 . The pallet according to  claim 1 , wherein the block members are press-formed.  
   
   
       13 . The pallet according to  claim 1 , wherein the block members are formed using extrusion techniques.  
   
   
       14 . The pallet according to  claim 1 , wherein the natural material particles have an average particle size of less than about 0.25 inches and have a random orientation in the composite material.  
   
   
       15 . The pallet according to  claim 14 , wherein the natural material particles have an average particle size of less than about 0.0625 inches.  
   
   
       16 . A pallet comprising: 
 a first deck comprising a first plurality of cross members;    a second deck comprising a second plurality of cross members; and    a plurality of block members connecting the first and second decks together to form a pallet, wherein at least one block member and at least one cross member of the first or second plurality of cross members comprise a composite material including at least about 50% by weight of a natural material and at least about 45% by weight of a plastic material comprising a major portion of polyethylene.    
   
   
       17 . The pallet according to  claim 16 , wherein the at least one cross member comprises a lead board.  
   
   
       18 . The pallet according to  claim 16 , wherein the at least one cross member comprises a composite material including wood fibers having an average length of from about ⅜ to about ¾ inches.  
   
   
       19 . The pallet according to  claim 16 , wherein the plastic material comprises at least one material selected from the group consisting of polypropylene, polyethylene, polyurethane, polyvinylchloride, poly(ethylene terephthalate), nylon, and mixtures thereof.  
   
   
       20 . The pallet according to  claim 16 , wherein the block members further comprise at least one filler selected from the group consisting of colorants, UV protectors, flame and fire retardants, lubricants, soaps, polymer initiators, coupling agents, and mixtures thereof.  
   
   
       21 . A pallet comprising: 
 a first deck comprising a first plurality of cross members;    a second deck comprising a second plurality of cross members; and    a plurality of extruded, elliptical shaped composite block members connecting the first and second decks together to form a pallet, wherein the block members and at least one cross member of the first or second plurality of cross members comprise a composite material including from about 50% to about 55% by weight of natural material particles having an average particles size of less than about 0.25 inches, and from about 45% to about 50% by weight of plastic material particles comprising a major portion of recycled, low density polyethylene.    
   
   
       22 . A method of making a pallet comprising: 
 preparing and blending a mixture comprising from about 50% to about 55% by weight of natural material particles and from about 45% to about 50% by weight of plastic material particles;    heating and extruding the mixture forming a composite material of a desired shape;    cutting the composite material into blocks; and    securing the blocks to substantially rectangular shaped upper and lower decks to form a pallet.