Multi-cell reciprocating conveyor slat and method of manufacture and non-continuous guide structure

Abstract

A pultruded slat for a reciprocating slat conveyor system comprises a slat body including a top portion, a first side portion, and a second side portion, the first and second side portions depending downwardly from opposite lengthwise sides of the top portion; wherein the first side portion and second side portion each include projections extending toward an opposing side portion, wherein the top portion of the slat body comprises a plurality of closed cells, and wherein a bottom of the top portion, the first side portion, the second side portion, and the projections comprise an open cell.

What is claimed:  
     
         1 . A slat for a reciprocating slat conveyor system comprising: 
 a slat body including a top portion, a first side portion, and a second side portion, said first and second side portions depending downwardly from opposite lengthwise sides of said top portion;    wherein said first side portion and second side portion each include projections extending toward an opposing side portion,    wherein said top portion of said slat body comprises a plurality of closed cells,    wherein a bottom of said top portion, said first side portion, said second side portion, and said projections comprise an open cell.    
     
     
         2 . A slat for a reciprocating slat conveyor system according to  claim 1 , wherein said top portion of said slat body comprises two closed cells extending along at least substantially an entire length of said slat.  
     
     
         3 . A slat for a reciprocating slat conveyor system according to claim any of claims  1 - 2 , wherein said top portion of said slat body comprises two closed cells extending along a portion of said slat.  
     
     
         4 . A slat for a reciprocating slat conveyor system according to claim any of claims  1 - 3 , wherein said top portion of said slat body comprises a plurality of closed cells dispersed along a length of said slat.  
     
     
         5 . A slat for a reciprocating slat conveyor system according to any of claims  1 - 4 , wherein said top portion of said slat body comprises a plurality of closed cells evenly dispersed along a length of said slat.  
     
     
         6 . A slat for a reciprocating slat conveyor system according to any of claims  1 - 5 , wherein said plurality of closed cells collectively comprise at least half of an interior volume of said top portion of said slat.  
     
     
         7 . A slat for a reciprocating slat conveyor system according to any of claims  1 - 6 , wherein said plurality of closed cells are pressurized.  
     
     
         8 . A slat for a reciprocating slat conveyor system according to any one of claims  1 - 7 , wherein said top portion comprises reinforcing members.  
     
     
         9 . A slat for a reciprocating slat conveyor system according to  claim 8 , wherein said reinforcing members comprise longitudinally extending reinforcing fibers.  
     
     
         10 . A slat for a reciprocating slat conveyor system according to  claim 8 , wherein said reinforcing members comprise at least one of z-axis reinforcing fibers and y-axis fibers.  
     
     
         11 . A slat for a reciprocating slat conveyor system according to  claim 8 , wherein said reinforcing members comprise at least one of a continuous z-stitch or a discontinuous z-stitch.  
     
     
         12 . A slat for a reciprocating slat conveyor system according to  claim 1 , further comprising a guide block configured for lengthwise insertion and sliding movement within said open cell, said guide block disposed on top of a cross-member.  
     
     
         13 . A slat for a reciprocating slat conveyor system according to  claim 12 , wherein a width of said guide block is substantially equal to a width of said cross-member along a direction perpendicular to a direction of reciprocating movement of a slat.  
     
     
         14 . A continuous profile molding method for manufacturing a slat for a reciprocating slat conveyor system comprising the steps of: 
 arranging a plurality of fibers into a shape of at least a top portion of a lengthwise slat body, said slat body comprising a top portion, a first side portion, and a second side portion, said first and second side portions depending downwardly from opposite lengthwise sides of said top portion; wherein said first side portion and second side portion each include projections extending toward an opposing side portion, wherein said top portion of said slat body comprises a plurality of closed cells, wherein a bottom of said top portion, said first side portion, said second side portion, and said projections comprise an open cell;    applying a thermoplastic or thermosetting resin onto said fibers;    moving said fibers bearing said thermoplastic or thermosetting resin through a die, wherein said fibers bearing said thermoplastic or thermosetting resin are heated to a temperature sufficient to melt said resin and are compressed to form said slat body.    
     
     
         15 . A continuous profile molding method for manufacturing a slat for a reciprocating slat conveyor system according to  claim 14 , wherein said arranging step comprises arranging at least one of a plurality of lengthwise fibers and z-fibers.  
     
     
         16 . A reciprocating slat conveyor system having a plurality of adjacent conveyor slats mounted to be selectively reciprocated endwise, comprising: 
 a plurality of elongated slat bodies extending in and reciprocatingly moving in a first direction, said elongated slat bodies including a top portion, a first side portion, and a second side portion, said first and second side portions depending downwardly from opposite lengthwise sides of said top portion, wherein said first side portion and second side portion each include projections extending toward an opposing side portion, wherein said top portion of said slat body comprises a plurality of closed cells, and wherein a bottom of said top portion, said first side portion, said second side portion, and said projections comprise an open cell;    a plurality of guide blocks mounted to a top surface of cross members extending in a second direction perpendicular to said first direction.    
     
     
         17 . A reciprocating slat conveyor system according to  claim 16 , wherein said guide blocks extend in a first direction to cover a respective portion of a cross member.  
     
     
         18 . A reciprocating slat conveyor system according to  claim 17 , wherein said guide blocks are attached to a cross member by a mechanical fastener.  
     
     
         19 . A reciprocating slat conveyor system according to  claim 17 , further comprising a drive system.