Pallet And Method For Manufacturing The Same

Abstract

A pallet and a method for manufacturing the same are provided. The pallet comprises a pallet body, a skid to reinforce the pallet body and means to interlock the pallet body and the skid. The pallet body and the skid are moulded from a mouldable composition comprising between about 40 to 60 wt % of a fibre mixture and between about 15 to 45 wt % of an adhesive. The method for manufacturing the pallet begins by preparing the mouldable composition. A mould cavity is loaded with the mouldable composition up to about 90% of the capacity of the mould cavity before applying a packing pressure of between about 435 to 870 psi to the mouldable composition. A predetermined clearance of between about 0.1 to 0.5 mm is maintained between a first mould part defining the mould cavity and a second mould part. A moulded product is removed from the mould cavity when the mouldable composition is substantially cured.

1 . A biodegradable pallet comprising: 
 a pallet body;    a skid to reinforce the pallet body; and    means for interlocking the pallet body and the skid, wherein the pallet body and the skid are moulded from a mouldable composition comprising: 
 between about 40 to 60 wt % of a fibre mixture; and  
 between about 15 to 45 wt % of an adhesive.  
   
   
   
       2 . The pallet according to  claim 1 , wherein a moisture content of the mouldable composition is less than about 20%.  
   
   
       3 . The pallet according to  claim 2 , wherein a moisture content of the mouldable composition is between about 4 to 15%.  
   
   
       4 . The pallet according to  claim 2 , wherein a moisture content of the fibre mixture is less than about 15%.  
   
   
       5 . The pallet according to  claim 3 , wherein the mouldable composition further comprises not more than about 40 wt % of an additive.  
   
   
       6 . The pallet according to  claim 5 , wherein the additive is one or more of a group consisting of a hardener, a flow promoter and a mould release agent.  
   
   
       7 . The pallet according to  claim 1 , wherein the fibre mixture comprises a plurality of fibres and wherein each of the plurality of fibres is of a length of up to about 50 mm.  
   
   
       8 . The pallet according to  claim 7 , wherein each of the plurality of fibres is of a thickness of up to about 2 mm.  
   
   
       9 . The pallet according to  claim 8 , wherein each of the plurality of fibres is of a length to a thickness ratio of between about 2:1 to 25:1.  
   
   
       10 . The pallet according to  claim 1 , wherein the fibre mixture further comprises between about 5 to 30 wt % of an oil palm fibre.  
   
   
       11 . The pallet according to  claim 1 , wherein fibre mixture further comprises one of a group consisting of oil palm fibres, beer malt, sugarcane pulp, a plasticizer, a toughening agent and an impact modifier.  
   
   
       12 . The pallet according to  claim 1 , wherein the adhesive is a thermosetting resin.  
   
   
       13 . The pallet according to  claim 12 , wherein the adhesive is an amino resin.  
   
   
       14 . The pallet according to  claim 12 , wherein the adhesive is a melamine.  
   
   
       15 . The pallet according to  claim 14 , wherein the adhesive is one of a group consisting of melamine formaldehyde and melamine urea formaldehyde.  
   
   
       16 . The pallet according to  claim 1 , wherein the pallet body comprises a load-bearing member having a leg.  
   
   
       17 . The pallet according to  claim 16 , wherein the load-bearing member has a substantially constant overall wall thickness of between about 3 to 5 mm.  
   
   
       18 . The pallet according to  claim 16 , wherein the load-bearing member includes a plurality of ribs.  
   
   
       19 . The pallet according to  claim 18 , wherein each of the plurality of ribs comprises an open channel.  
   
   
       20 . The pallet according to  claim 19 , wherein the open channel has a tapering channel wall.  
   
   
       21 . The pallet according to  claim 18 , wherein each of the plurality of ribs is designed to have a draft angle of between about 6 to 120 from perpendicular to a surface of the load-bearing member.  
   
   
       22 . The pallet according to  claim 16 , wherein the leg is formed as a concave depression in the load-bearing member.  
   
   
       23 . The pallet according to  claim 16 , wherein the leg tapers inwards towards a base.  
   
   
       24 . The pallet according to  claim 23 , wherein the leg is designed to have a draft angle of between about 11 to 120 from perpendicular to a surface of the load-bearing member.  
   
   
       25 . The pallet according to  claim 23 , wherein the leg is designed to have a minimum vertical height of about 95 mm.  
   
   
       26 . The pallet according to  claim 23 , wherein a blind hole is provided on the base.  
   
   
       27 . The pallet according to  claim 26 , wherein the blind hole is designed to have a draft angle of less than about 0.5° from perpendicular to a surface of the load-bearing member.  
   
   
       28 . The pallet according to  claim 16 , wherein a first fillet is formed where the leg meets the load-bearing member.  
   
   
       29 . The pallet according to  claim 16 , wherein a fin is provided around a periphery of the load-bearing member.  
   
   
       30 . The pallet according to  claim 1 , wherein the skid comprises a framework formed from a plurality of ties.  
   
   
       31 . The pallet according to  claim 30 , wherein a second fillet is formed at a junction where the plurality of ties is joined.  
   
   
       32 . The pallet according to  claim 26 , wherein the skid includes a protruding plug corresponding to the blind hole in the base of the leg.  
   
   
       33 . The pallet according to  claim 32 , wherein the blind hole interlocks the protruding plug.  
   
   
       34 . The pallet according to  claim 33 , wherein a circumferential dimension of the protruding plug is between about 0.05 mm to 0.1 mm larger than a circumferential dimension of the blind hole.  
   
   
       35 . The pallet according to  claim 34 , wherein an interference fit secures the skid to the pallet body when a force is applied to interlock the blind hole and the protruding plug.  
   
   
       36 . The pallet according to  claim 32 , wherein the protruding plug is designed to have a draft angle of less than about 0.5° from perpendicular to a surface of the skid.  
   
   
       37 . The pallet according to  claim 1 , wherein the pallet is designed to have at least about 60% top deck coverage.  
   
   
       38 . The pallet according to  claim 1 , wherein the pallet is designed to have at least about 35% bottom deck coverage.  
   
   
       39 . A method for manufacturing a biodegradable pallet, the method comprising: 
 preparing a biodegradable mouldable composition, the mouldable composition comprising: 
 between about 40 to 60 wt % of a fibre mixture; and  
 between about 15 to 45 wt % of an adhesive,  
   loading a mould cavity with the mouldable composition, wherein the mould cavity is loaded up to about 90% of the capacity of the mould cavity;    applying a packing pressure of between about 435 to 870 psi to the mouldable composition;    maintaining a predetermined clearance of between about 0.1 to 0.5 mm between a first mould part defining the mould cavity and a second mould part; and    removing the moulded product from the mould cavity when the mouldable composition is substantially cured.    
   
   
       40 . The method according to  claim 39 , wherein the pressure is applied for a period of between about 20 to 60 s.  
   
   
       41 . The method according to  claim 40 , wherein the first mould part and the second mould part are maintained at a temperature of between about 110 to 180° C.  
   
   
       42 . The method according to  claim 41 , wherein the first mould part is maintained at a temperature of about 20° C. higher than a temperature of the second mould part.  
   
   
       43 . The method according to  claim 40 , further comprising: 
 increasing the predetermined clearance between the first mould part and the second mould part when the mouldable composition is about 90% cured.    
   
   
       44 . The method according to  claim 43 , wherein the predetermined clearance is increased to about 10 mm.  
   
   
       45 . The method according to  claim 44 , further comprising: 
 compressing the moulded product to a desired thickness.    
   
   
       46 . The method according to  claim 45 , further comprising: 
 ironing a surface of the moulded product.    
   
   
       47 . The method according to  claim 46 , wherein compressing the moulded product to the desired thickness and ironing the surface of the moulded product further comprises: 
 reducing the predetermined clearance to between about 0.05 to 0.3 mm.    
   
   
       48 . The method according to  claim 47 , wherein the predetermined clearance is reduced for between about 15 to 60 s.  
   
   
       49 . The method according to  claim 39 , wherein a moisture content of the mouldable composition is less than about 20%.  
   
   
       50 . The method according to  claim 49 , wherein a moisture content of the mouldable composition is between about 4 to 15%.  
   
   
       51 . The method according to  claim 49 , wherein a moisture content of the fibre mixture is less than about 15%.  
   
   
       52 . The method according to  claim 50 , wherein the mouldable composition further comprises not more than about 40 wt % of an additive.  
   
   
       53 . The method according to  claim 52 , wherein the additive is one or more of a group consisting of a hardener, a flow promoter and a mould release agent.  
   
   
       54 . The method according to  claim 39 , wherein the fibre mixture comprises a plurality of fibres and wherein each of the plurality of fibres is of a length of up to about 50 mm.  
   
   
       55 . The method according to  claim 54 , wherein each of the plurality of fibres is of a thickness of up to about 2 mm.  
   
   
       56 . The method according to  claim 55 , wherein each of the plurality of fibres is of a length to a thickness ratio of between about 2:1 to 25:1.  
   
   
       57 . The method according to  claim 39 , wherein the fibre mixture further comprises between about 5 to 30 wt % of an oil palm fibre.  
   
   
       58 . The method according to  claim 39 , wherein fibre mixture further comprises one of a group consisting of oil palm fibres, beer malt, sugarcane pulp, a plasticizer, a toughening agent and an impact modifier.  
   
   
       59 . The method according to  claim 39 , wherein the adhesive is a thermosetting resin.  
   
   
       60 . The method according to  claim 59 , wherein the adhesive is an amino resin.  
   
   
       61 . The method according to  claim 59 , wherein the adhesive is a melamine.  
   
   
       62 . The method according to  claim 61 , wherein the adhesive is one of a group consisting of melamine formaldehyde and melamine urea formaldehyde.  
   
   
       63 . The method according to  claim 39 , wherein preparing the mouldable composition comprises: 
 weighing each component of the mouldable composition individually; and    combining each component of the mouldable composition in a mixer to form a substantially homogeneous and well-coated mouldable composition.    
   
   
       64 . The method according to  claim 63 , wherein preparing the mouldable composition further comprises: 
 combining each liquid component of the mouldable composition in a second mixer to form a liquid mixture.    
   
   
       65 . The method according to  claim 64 , wherein preparing the mouldable composition further comprises: 
 spraying the liquid mixture into the mixer.    
   
   
       66 . The method according to  claim 65 , wherein the mixer is operated at a rotor speed of about 29 rpm.  
   
   
       67 . The method according to  claim 39 , wherein a vent is provided by maintaining a predetermined clearance between respective parts of the mould adjacent the mouldable composition.  
   
   
       68 . The method according to  claim 67 , wherein the vent is temporarily occluded by the mouldable composition in the mould to temporarily prevent release of moisture vapour for a predetermined period.  
   
   
       69 . The method according to  claim 68 , wherein the moisture vapour content is controlled to generate bubbles of the vapour in the mouldable composition and thereby produce a porous moulded product of predetermined density.  
   
   
       70 . A method for manufacturing a biodegradable pallet, the method comprising: 
 loading a cavity of a mould with a biodegradable mouldable composition comprising between about 40 to 60 wt % of a fibre mixture and between about 15 to 45 wt % of an adhesive, wherein the cavity is loaded up to about 90% of the capacity of the cavity;    activating the mould so as to apply a packing pressure in the range 435 to 870 psi to the mouldable composition therein;    providing a moisture vapour vent responsive to pressure in the mouldable composition and set to provide a predetermined control of moisture vapour content and thereby pressure in the composition, whereby to produce a moulded product having predetermined density and strength; and    removing the moulded product from the mould cavity when the mouldable composition is substantially cured.    
   
   
       71 . The method according to  claim 70  wherein the vent is provided by maintaining a predetermined clearance between respective parts of the mould adjacent the mouldable composition.  
   
   
       72 . The method according to  claim 70  wherein the vent is temporarily occluded by the mouldable composition in the mould to temporarily prevent release of moisture vapour for a predetermined period.  
   
   
       73 . The method according to  claim 70  wherein the moisture vapour content is controlled to generate bubbles of the vapour in the mouldable composition and thereby produce a porous moulded product of predetermined density.  
   
   
       74 . The method according to  claim 70 , further comprising: 
 increasing the predetermined clearance between the first mould part and the second mould part when the mouldable composition is about 90% cured.    
   
   
       75 . The method for manufacturing a pallet according to  claim 74 , wherein the predetermined clearance is increased to about 10 mm.  
   
   
       76 . The method for manufacturing a pallet according to  claim 75 , further comprising: 
 compressing the moulded product to a desired thickness.    
   
   
       77 . The method for manufacturing a pallet according to  claim 76 , further comprising: 
 ironing a surface of the moulded product.    
   
   
       78 . The method for manufacturing a pallet according to  claim 77 , wherein compressing the moulded product to the desired thickness and ironing the surface of the moulded product further comprising: 
 reducing the predetermined clearance to between about 0.05 to 0.3 mm.    
   
   
       79 . A pallet produced by the method according to  claim 39.