Co-extruded pallet block

Abstract

A pallet block includes an extruded inner core and an outer shell co-extruded with the inner core. The outer shell surrounds the inner core with respect to an extrusion axis defined by the inner core. The compositions of the inner core and outer shell differ by one or both of mass density and formula. For example, the outer shell may have a higher mass density than the inner core and may protect the inner core from impact and moisture ingression. Each of the inner core and outer shell may include product-packaging waste.

1 . A pallet block comprising:
 an extruded inner core defining an extrusion axis, the inner core comprising a foamed composition of plastic and at least one of paper, wood, and metal;   an outer shell co-extruded with the inner core, the outer shell surrounding the inner core with respect to the extrusion axis, the outer shell comprising plastic and at least one of paper, wood, and metal;   wherein the mass density of the outer shell is greater than the mass density of the inner core.   
   
   
       2 . The pallet block of  claim 1 , wherein the outer shell contains more plastic per gram than the inner core contains plastic per gram. 
   
   
       3 . The pallet block of  claim 1 , wherein the outer shell comprises a foamed composition of plastic, and at least one of paper, wood, and metal. 
   
   
       4 . The pallet block of  claim 3 , wherein the inner core is more foamed than the outer shell. 
   
   
       5 . The pallet block of  claim 1 , wherein the inner core comprises product-packaging waste. 
   
   
       6 . A pallet comprising:
 at least one pallet member;   a pallet block attached to the pallet member, the pallet bock comprising:
 an extruded inner core defining an extrusion axis, the inner core comprising a foamed composition of at least one of plastic, paper, wood, and metal; 
 an outer shell co-extruded with the inner core, the outer shell surrounding the inner core with respect to the extrusion axis, the outer shell comprising plastic; 
 wherein the mass density of the outer shell is greater than the mass density of the inner core. 
   
   
   
       7 . The pallet of  claim 6 , wherein the pallet member comprises a deckboard, a stringer, or a pallet deck. 
   
   
       8 . The pallet of  claim 6 , wherein the pallet member has a generally planar surface to which the pallet block is attached, and wherein the extrusion axis defined by the inner core is disposed essentially perpendicular to the generally planar surface of the pallet member. 
   
   
       9 . The pallet of  claim 6 , wherein the pallet block is attached to the pallet member by way of an elongate connector disposed essentially parallel to the extrusion axis defined by the inner core. 
   
   
       10 . The pallet of  claim 9 , wherein the elongate connector is retained by the inner core without the elongate connector contacting the outer shell. 
   
   
       11 . The pallet block of  claim 6 , wherein the outer shell contains more plastic per gram than the inner core contains plastic per gram. 
   
   
       12 . The pallet block of  claim 6 , wherein the outer shell comprises plastic and at least one of plastic, paper, wood, and metal. 
   
   
       13 . A cargo item comprising:
 a payload;   a pallet member disposed beneath and at least partially supporting the payload; and   a pallet block disposed beneath and at least partially supporting the pallet member and payload, the pallet block comprising an extruded inner core and an outer shell co-extruded with the inner core, the outer shell surrounding the inner core with respect to a vertical axis.   
   
   
       14 . The cargo item of  claim 13 , wherein the outer shell differs from the inner core in at least one of formula and mass density. 
   
   
       15 . The cargo item of  claim 13 , wherein the pallet member and pallet block are connected together by a vertically disposed nail or screw. 
   
   
       16 . The cargo item of  claim 15 , wherein said nail or screw is retained by the inner core, and wherein said nail or screw does not penetrate the outer shell. 
   
   
       17 . The cargo item of  claim 13 , wherein the inner core comprises a foamed composition of plastic and at least one of paper, wood, and metal. 
   
   
       18 . The cargo item of  claim 17 , wherein the mass density of the outer shell is greater than the mass density of the inner core. 
   
   
       19 . The cargo item of  claim 17 , wherein the outer shell comprises plastic and at least one of plastic, paper, wood, and metal. 
   
   
       20 . The cargo item of  claim 13 , wherein the inner core comprises product-packaging waste.