Load bearing structure with inserts

Abstract

A load-bearing platform that includes an expandable polymer matrix core and a skin disposed over a bottom side of the core. The core includes a base and a plurality of legs extending from one side of the base, the legs having one or more core insert openings in a bottom surface of the legs. The skin includes a plurality of legs, each adapted to accept a leg of the core and one or more skin insert openings corresponding to a core insert opening, where at least one leg insert per leg is inserted into an insert opening. The load bearing platform can be used for shipping articles.

1 . A load-bearing platform comprising an expandable polymer matrix core and a skin disposed over a bottom side of the core wherein
 the core comprises a base and a plurality of legs extending from one side of the base, the legs having one or more core insert openings in a bottom surface of the legs, and   the skin comprises a plurality of legs, each adapted to accept a leg of the core and one or more skin insert openings corresponding to a core insert opening;   and wherein at least one leg insert per leg is inserted into an insert opening.   
   
   
       2 . The load-bearing platform according to  claim 1 , wherein the expandable polymer matrix comprises one or more expandable plastics. 
   
   
       3 . The load-bearing platform according to  claim 1 , wherein the expandable plastics are one or more selected from the group consisting of interpolymers of one or more polyolefins and in situ polymerized vinyl aromatic monomers, expandable polystyrene, expandable styrenic polymers, expandable polyolefins, rubber modified styrenic polymers where the styrenic polymer constitutes a continuous phase and the rubber constitutes a dispersed phase in the resin, rubber modified styrenic polymers where the rubber constitutes a continuous phase and the styrenic polymer-constitutes a dispersed phase in the resin, polyphenylene oxide, and combinations and blends thereof. 
   
   
       4 . The load-bearing platform according to  claim 3 , wherein the polyolefins are selected from the group consisting of low density polyethylene, medium density polyethylene, high density polyethylene, an ethylene vinyl acetate copolymer, an ethylene/propylene copolymer, a blend of polyethylene and polypropylene, a blend of polyethylene and an ethylene/vinyl acetate copolymer, and a blend of polyethylene and an ethylene/propylene copolymer, ethylene-butyl acrylate copolymer, ethylene-methyl methacrylate copolymer and combinations thereof. 
   
   
       5 . The load-bearing platform according to  claim 3 , wherein the vinyl aromatic monomers are selected from the group consisting of styrene, alpha-methylstyrene, ethylstyrene, chlorostyrene, bromostyrene, vinyltoluene, vinylbenzene, and isopropylxylene and admixtures thereof. 
   
   
       6 . The load-bearing platform according to  claim 1 , wherein the expandable polymer matrix comprises a blowing agent and/or plasticizer. 
   
   
       7 . The load-bearing platform according to  claim 1 , wherein the expandable polymer matrix comprises polymers selected from the group consisting of expandable polystyrene, expandable polyolefins, rubber modified styrenic polymers where the styrenic polymer constitutes a continuous phase and the rubber constitutes a dispersed phase in the resin, rubber modified styrenic polymers where the rubber constitutes a continuous phase and the styrenic polymer constitutes a dispersed phase in the resin, polyphenylene oxide, and combinations and blends thereof. 
   
   
       8 . The load-bearing platform according to  claim 3 , wherein the expandable polymer contains from 25 to 99% based on the weight of the expandable polymer matrix of interpolymers of a polyolefin and in situ polymerized vinyl aromatic monomers and from 1 to 75% based on the weight of the expandable polymer matrix of other expandable polymers. 
   
   
       9 . The load-bearing platform according to  claim 1 , wherein the load bearing platform is in the shape of a rectangle and has an edge of from 1 to 25 cm, a length of from 75 to 150 cm and a width of from 65 to 140 cm. 
   
   
       10 . The load-bearing platform according to  claim 1  comprising a layer material applied to a topside of the platform. 
   
   
       11 . The load-bearing platform according to  claim 1 , wherein a continuous or discontinuous groove or channel is molded or cut into a surface of a topside of the base such that the groove or channel follows the perimeter of the topside and a first edge of the groove or channel is spaced apart from an outer edge of the base. 
   
   
       12 . The load-bearing platform according to  claim 11  comprising a plurality of panels adapted to fit into the groove or channel. 
   
   
       13 . The load-bearing platform according to  claim 12  comprising a top panel that matches the width and length of the load bearing structure and includes a groove or channel matching the groove or channel in the topside and is adapted to accept a top surface of the panels to form a box or open box structure. 
   
   
       14 . The load-bearing platform according to  claim 1 , wherein the leg inserts comprise
 a base having a top surface and bottom surface;   a thickness defined as the distance between top surface and bottom surface that is larger at a center portion than at an edge of the base; and   two or more fingers extending perpendicular from the top surface of the base.   
   
   
       15 . The load-bearing platform according to  claim 14 , wherein a gripping means is included at a terminal end of the fingers. 
   
   
       16 . The load-bearing platform according to  claim 14 , wherein the gripping means is selected from the group consisting of a shoulder, knobs, buttons, ribs, teeth, and a collar. 
   
   
       17 . The load-bearing platform according to  claim 14 , wherein the ratio of widest diameter of terminal ends of the fingers and the diameter of the insert opening is at least 1.001. 
   
   
       18 . The load-bearing platform according to  claim 1 , wherein the leg inserts are made of a material selected from the group consisting of hard plastics, metals, ceramics, composite materials, and combinations of such materials. 
   
   
       19 . The load-bearing platform according to  claim 1 , wherein the skin comprises one or more materials selected from the group consisting of homopolymers and copolymers of styrene, homopolymers and copolymers of C 2  to C 20  olefins, homopolymers and copolymers of C 4  to C 20  dienes, polyesters, polyamides, homopolymers and copolymers of C 2  to C 20  (meth)acrylate esters, polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides, copolymers of styrene, C 4  to C 20  dienes and (meth)acrylonitrile polyurethanes, and combinations thereof. 
   
   
       20 . The load-bearing platform according to  claim 18 , wherein one or more materials selected from the group consisting of carbon fibers, aramid fibers, glass fibers, metal fibers, woven fabric or structures of the mentioned fibers, fiberglass, carbon black, graphite, clays, calcium carbonate, titanium dioxide, woven fabric or structures of the above-referenced fibers, and combinations thereof are incorporated into the thermoplastic materials. 
   
   
       21 . The load-bearing platform according to  claim 1 , wherein the skin has a thickness of from 0.1 mm to 1.5 mm. 
   
   
       22 . The load-bearing platform according to  claim 1 , wherein a device that provides a rolling mechanism is attached to the leg inserts. 
   
   
       23 . A method of shipping articles comprising loading articles onto a top surface of the load bearing platform according to  claim 1 .