Pallets

Abstract

The intention provides a method of coating wooden pallets having a low moisture content with an elastomer coating, so as to provide pallets combining the advantageous qualities of wooden and plastic pallets. The pallets are light and inexpensive, tough and durable, water and damage resistant, fire retardant and non-slip. They can be produced by treating existing wooden pallets. The pallets may also have an RFID attached before coating for tracking the pallets and goods transported thereon.

1 .- 46 . (canceled) 
     
     
         47 . A wooden pallet having a substantially monolithic continuous coating of an elastomer wherein the moisture content of the wooden pallet is less than 10% by weight of the wooden pallet. 
     
     
         48 . A wooden pallet having a monolithic, continuous coating of an elastomer wherein the coating comprises one or more additives selected from flame retardants, anti-slip additives and biocides. 
     
     
         49 . The wooden pallet as claimed in  claim 47  wherein the coating of elastomer has a thickness of from 1 to 5 mm, preferably from 1 to 3 mm, more preferably about 2 mm. 
     
     
         50 . The wooden pallet as claimed in  claim 47  wherein the coating of elastomer comprises a flame retardant additive, wherein the flame retardant additive may be selected from hydrated fillers, halogen-containing materials, phosphorus-containing materials, antimony-containing materials and intumescent materials, or wherein the flame retardant additive is aluminium trihydrate. 
     
     
         51 . The wooden pallet as claimed in  claim 50  wherein the flame retardant is present in an amount of from 40 to 70% by weight of the coating of elastomer, or wherein the flame retardant is present in an amount of from 50 to 60% by weight of the coating of elastomer. 
     
     
         52 . The wooden pallet as claimed in  claim 47  wherein the coating of elastomer comprises at least one of: an anti-slip additive, for example selected from polymer particles and mineral particles; a biocide, for example a fungicide; a colouring agent for example selected from dyes and pigments; and an ultraviolet light stabilizer. 
     
     
         53 . The wooden pallet as claimed in  claim 47  wherein the elastomer is selected from polyurethane, polyurea, polyaspartics, epoxy, polyurethane-polyurea hybrids or any combination thereof, or wherein the elastomer is polyurethane, which may be formed by reaction of diphenylmethane-4-4′-diisocyanate and a polyol, or by reaction of Bayflex 89-624 and Desmodur 1327. 
     
     
         54 . The wooden pallet as claimed in  claim 47  wherein the wooden pallet comprises and identity marker, which may be beneath the coating of elastomer, and which may be an RFID tag. 
     
     
         55 . A wooden pallet having an RFID tag attached thereto, and a monolithic continuous coating of elastomer encapsulating the pallet and the tag. 
     
     
         56 . A method of producing a pallet as claimed in  claim 47  comprising: drying a wooden pallet to a moisture content below about 10%, and applying an elastomer coating over the outside surface of the pallet. 
     
     
         57 . The method as claimed in  claim 56 , comprising machining the outer surface of the pallet to within predetermined tolerances for coating before applying the elastomer coating, for example by machining the surfaces of the pallet to substantially even surfaces using a router, and preferably comprising inspecting the pallet to determine whether the pallet is within predetermined dimensional tolerances for machining before machining the pallet. 
     
     
         58 . The method as claimed in  claim 56 , comprising applying an RFID tag to an inner surface of the pallet before applying the elastomer coating, for example to a surface of a central member of the pallet which extends perpendicular to a load surface of the pallet, in which the RFID tag may be heat resistant, for example being formed substantially of plastics material, and in which the tag may be applied using a heat resistant attachment member formed substantially of plastics material. 
     
     
         59 . The method as claimed in  claim 58 , comprising reading the RFID tag on the finished pallet, and storing the pallet for collection in a location according to information obtained from the tag. 
     
     
         60 . The method as claimed in  claim 56 , comprising drying the pallet in a kiln. 
     
     
         61 . The method as claimed in  claim 56 , in which coating the pallet comprises spray coating, for example by coating a central member of the pallet, coating the remainder of the surfaces exposed to the spray coater, gripping the pallet using the coated central member, and manipulating the pallet to expose the remaining surfaces to the coater, in which the pallet may be manipulated by a robot, and the spray head may be movable. 
     
     
         62 . The method as claimed in  claim 56 , comprising checking the finish of the coated pallet using a camera. 
     
     
         63 . A method of processing wooden pallets comprising:
 receiving a wooden pallet for coating;   inspecting the pallet;   applying an RFID tag to an inner surface of the pallet containing information concerning the pallet;   drying the pallet in a kiln;   machining the surfaces of the pallet to predetermined tolerances, excluding the area where   
       the RFID tag is positioned;
 coating the pallet with elastomer material using a spray coater; 
 inspecting the pallet for finish; 
 reading the RFID tag; and 
 storing the pallet for collection according to information obtained from the tag. 
 
     
     
         64 . The method as claimed in  claim 63 , in which applying the elastomer coating comprises mixing a two part elastomer, at least one of the parts comprising at least one of and preferably all of a fire retardant, an anti-slip, and a biocide additive, and comprising adding a dye to the mixed elastomer, the colour of the dye being selected according to predetermined criteria. 
     
     
         65 . A wooden pallet having an RFID tag attached thereto and a substantially continuous coating of elastomer encapsulating the pallet and the tag. 
     
     
         66 . A system for producing a supply of pallets according to  claim 47 , comprising a receiving arrangement for receiving multiple pallets, an inspection apparatus, a tagging facility, a drying station, a machining facility, a coating station, an output bay and conveying means for conveying pallets through the system wherein the system is arranged to perform a method according to  claim 56 , and preferably wherein the system is arranged to perform both programmed processing of pallets arriving and optionally to perform further processing specific to individually identified pallets.