Thermoplastic pallet having foam-filled or foam-coated structural parts

Abstract

Improved structural parts of a thermoplastic plastic pallet include foam, provided within hollows of the structural component and/or upon the surfaces of the component to provide improved fire resistance.

1 . A plastic pallet, comprising a thermoplastic structural pallet member including a foam thereon.  
   
   
       2 . A plastic pallet in accordance with  claim 1 , wherein the thermoplastic structural pallet member comprises polypropylene or high density polyethylene.  
   
   
       3 . A plastic pallet in accordance with  claim 1 , wherein the structural pallet member is hollow and at least partially filled with foam.  
   
   
       4 . A plastic pallet in accordance with  claim 3 , wherein the structural pallet member is a pallet column.  
   
   
       5 . A plastic pallet in accordance with  claim 3 , wherein the structural pallet member is a deck.  
   
   
       6 . A plastic pallet in accordance with  claim 3 , wherein the amount of foam is varied between different parts of the structural pallet member.  
   
   
       7 . A plastic pallet in accordance with  claim 1 , wherein the amount of foam provided on the structural pallet member is varied along different parts of the structural pallet member.  
   
   
       8 . A plastic pallet in accordance with  claim 3 , wherein foam is provided at least partially within a hollow of the structural pallet member as well as on at least a portion of the exterior.  
   
   
       9 . A plastic pallet in accordance with  claim 1 , wherein the foam is a thermoset polymer foam.  
   
   
       10 . A plastic pallet in accordance with  claim 9 , wherein the foam is a polyurethane foam.  
   
   
       11 . A plastic pallet in accordance with  claim 9 , wherein the foam is a low density polyurethane foam.  
   
   
       12 . A plastic pallet in accordance with  claim 1 , wherein the foam is a ceramic or glass or expanded mineral foam.  
   
   
       13 . A plastic pallet in accordance with  claim 1 , wherein the foam further includes a fire retardant.  
   
   
       14 . A plastic pallet in accordance with  claim 13 , wherein the foam further includes 5-20 weight percent intumescent graphite .5-20 weight percent intumescent graphite.  
   
   
       15 . A plastic pallet in accordance with  claim 1 , wherein the foam covered section has a lower rate of heat release during a burn test, as compared the same section without foam.  
   
   
       16 . A plastic pallet in accordance with  claim 1 , wherein the foam covered section has a higher impact strength, as compared the same section without foam.  
   
   
       17 . A plastic pallet in accordance with  claim 1 , wherein the pallet comprises a metal deck and reinforcing beams in solid structural plastic portions.  
   
   
       18 . A plastic pallet in accordance with  claim 1 , wherein the structural pallet member approximates the cross section shape of I, H, C, or O.  
   
   
       19 . A plastic pallet in accordance with  claim 1 , wherein the structural pallet member includes lightening holes or filigree structure.  
   
   
       20 . A method of improving the fire resistance of a structural plastic member of a pallet, comprising filling hollow portions of the structural members with polymer foam or adhering polymer foam to external surfaces of said structural members.