Pallet With Recycled 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 may include at least one recycled thermoplastic component having at least about 20% by weight of a recycled nylon carpet material. In various embodiments, the composite block further includes at least one recycled material selected from the group consisting of bottling containers, automotive plastic components, agricultural films, rubber tires, fabrics, textiles, reclaimed paper, sanitary paper products, and mixtures thereof.

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 including at least one recycled thermoplastic component including at least about  20 % by weight of a recycled nylon carpet material.    
   
   
       2 . The pallet according to  claim 1 , wherein the block members further comprise natural material particles.  
   
   
       3 . The pallet according to  claim 1 , wherein the block members further comprise at least one recycled material selected from the group consisting of polypropylene, polyethylene, polyurethane, polyvinylchloride, poly(ethylene terephthalate), polystyrene, polybutadiene, and mixtures thereof.  
   
   
       4 . The pallet according to  claim 1 , wherein the block members further comprise at least one recycled material selected from the group consisting of bottling containers, automotive plastic components, agricultural films, rubber tires, fabrics, textiles, reclaimed paper, sanitary paper products, and mixtures thereof.  
   
   
       5 . The pallet according to  claim 1 , wherein the block members further comprise at least one prime or virgin material.  
   
   
       6 . 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 including at least about 20% by weight of recycled nylon material.  
   
   
       7 . The pallet according to  claim 6 , wherein the at least one cross member comprises a lead board.  
   
   
       8 . The pallet according to  claim 1 , wherein the block members comprise at least about 50% by weight of recycled nylon carpet material.  
   
   
       9 . The pallet according to  claim 1 , wherein the block members comprise at least about 75% by weight of recycled nylon carpet material.  
   
   
       10 . The pallet according to  claim 9 , wherein the block members comprise at least about 75% by weight of a recycled nylon carpet material including a major portion of nylon  6  and/or nylon  6 , 6 .  
   
   
       11 . 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, foaming agents, and mixtures thereof.  
   
   
       12 . The pallet according to  claim 1 , wherein the block members are formed using extrusion techniques.  
   
   
       13 . 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 include at least one recycled thermoplastic component including at least about 20% by weight of a recycled nylon carpet material.    
   
   
       14 . The pallet according to  claim 13 , wherein the at least one cross member comprises a lead board.  
   
   
       15 . The pallet according to  claim 13 , wherein the at least one block member and at least one cross member further comprise at least one recycled material selected from the group consisting of polypropylene, polyethylene, polyurethane, polyvinylchloride, poly(ethylene terephthalate), nylon, polystyrene, polybutadiene, and mixtures thereof.  
   
   
       16 . The pallet according to  claim 13 , wherein the at least one block member and at least one cross member 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, wood fibers, foaming agents, and mixtures thereof.  
   
   
       17 . The pallet according to  claim 13 , wherein the at least one block member and at least one cross member further comprise at least one recycled material selected from the group consisting of bottling containers, automotive plastic components, agricultural films, rubber tires, fabrics, textiles, reclaimed paper, sanitary paper products, and mixtures thereof.  
   
   
       18 . The pallet according to  claim 13 , wherein the at least one block member and at least one cross member comprise at least about 75% by weight of a recycled nylon carpet material including a major portion of nylon 6 and/or nylon 6,6.  
   
   
       19 . A method of making a pallet comprising: 
 preparing and blending a thermoplastic mixture comprising from about 20% to about 75% by weight of recycled nylon carpet material;    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.    
   
   
       20 . A method according to  claim 19 , wherein the thermoplastic mixture further comprises at least one recycled material selected from the group consisting of bottling containers, automotive plastic components, agricultural films, rubber tires, fabrics, textiles, reclaimed paper, sanitary paper products, and mixtures thereof.