Novel pallets

Abstract

The present invention is a novel pallet comprising conventional pallet coated with an elastomeric material, such as a polyurea. The present invention is further directed to a novel composite pallet comprising an elastomeric material, such as a polyurea, and one or more filler materials.

What is claimed is:  
     
         1 . A pallet comprising one or more structural elements and an elastomeric material, wherein the elastomeric material coats or encapsulates the one or more structural elements.  
     
     
         2 . The pallet of  claim 1 , wherein the one or more structural elements comprise wood boards and the elastomeric material forms a uniform, monolithic, continuous coating over the wooden boards.  
     
     
         3 . The pallet of  claim 2 , wherein the elastomeric material comprises a polyurea, polyurethane, polyaspartics, epoxy, polyurethane-polyurea hybrids or a combination thereof.  
     
     
         4 . The pallet of  claim 2 , wherein the elastomeric material comprises a polyurea.  
     
     
         5 . The pallet of  claim 2 , wherein the coating has a thickness of from about 1 mil to about 250 mils.  
     
     
         6 . The pallet of  claim 5 , wherein the coating has a thickness of from about 60 mils to about 75 mils.  
     
     
         7 . The pallet of  claim 1 , wherein the one or more structural elements comprise filler materials and the elastomeric material forms a continuous matrix encapsulating the filler materials.  
     
     
         8 . The pallet of  claim 7 , wherein the filler material comprises particulate material, fibers, a nonwoven fabric, a woven fabric, a knitted fabric, rods, or a combination thereof.  
     
     
         9 . The pallet of  claim 7 , wherein the filler material comprises glass fibers, a nonwoven glass fabric, a woven glass fabric or a combination thereof.  
     
     
         10 . The pallet of  claim 7 , wherein the elastomeric material comprises a polyurea, polyurethane, polyaspartics, epoxy, polyurethane-polyurea hybrids or a combination thereof.  
     
     
         11 . The pallet of  claim 10 , wherein the elastomeric material comprises a polyurethane foam.  
     
     
         12 . A method of making the pallet of  claim 1  comprising: 
 spraying the wood boards with the elastomeric material to form an uniform, monolithic, continuous coating over the wooden boards.  
 
     
     
         13 . A method of making the pallet of  claim 7  comprising: 
 placing filler materials in a mold with an elastomeric material;  
 molding the materials to form a high density composite panel;  
 cutting the composite panel into boards; and  
 adhering the boards to one another to form the pallet.  
 
     
     
         14 . The method of  claim 13 , wherein the boards are adhered to one another by nails, screws, adhesives or a combination thereof.  
     
     
         15 . An improved, waterproof, damage-resistant pallet comprising: 
 a wood or compressed wood pallet; and    an elastomeric material which forms an uniform, monolithic, continuous coating over the wood or compressed wood pallet.    
     
     
         16 . The pallet of  claim 15 , wherein the elastomeric material comprises a polyurea, polyurethane, polyaspartics, epoxy, polyurethane-polyurea hybrids or a combination thereof; and wherein the coating has a thickness of from about 1 mil to about 250 mils.  
     
     
         17 . The pallet of  claim 16 , wherein the coating has a thickness of from about 60 mils to about 75 mils.  
     
     
         18 . A pallet comprising: 
 a first plurality of composite boards in a first plane;    a second plurality of composite boards in a second plane;    a third plurality of composite boards positioned between the first plurality of composite boards and the second plurality of composite boards; and    attachment means for attaching the first plurality of composite boards and the second plurality of composite boards to the third plurality of composite boards; wherein the first, second and third plurality of composite boards comprise one or more filler materials and an elastomeric material which forms a continuous matrix encapsulating the one or more filler materials.    
     
     
         19 . The pallet of  claim 18 , wherein the filler material comprises glass fibers, a nonwoven glass fabric, a woven glass fabric or a combination thereof; and wherein the elastomeric material comprises a polyurea, polyurethane, polyaspartics, epoxy, polyurethane-polyurea hybrids or a combination thereof.  
     
     
         20 . The pallet of  claim 18 , wherein the composite boards have a density of from about 10 to about 40 pounds per cubic foot.  
     
     
         21 . The pallet of  claim 18 , further comprising a uniform, monolithic, continuous coating over the first, second and third plurality of composite boards and the attachment means.  
     
     
         22 . The pallet of  claim 21 , wherein the coating comprises a polyurea, polyurethane, polyaspartics, epoxy, polyurethane-polyurea hybrids or a combination thereof.  
     
     
         23 . The pallet of  claim 22 , wherein the coating comprises a polyurea.  
     
     
         24 . The pallet of  claim 21 , wherein the coating has a thickness of from about 1 mil to about 250 mils.