GB2476110A

GB2476110A - Transport pallet with insulating means

Info

Publication number: GB2476110A
Application number: GB0921777A
Authority: GB
Inventors: Paul Harrison
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-12-11
Filing date: 2009-12-11
Publication date: 2011-06-15
Also published as: GB0921777D0

Abstract

A transport pallet 20 is disclosed comprising a load supporting platform 22 supported above the ground in use by a plurality of feet 24 extending downwardly from an underside of the platform, said feet allowing access under said platform, said platform at least, having a platform core of foamed polymer material having a more rigid surface formed by a polymer coating, said coating being applied in liquid form after said core is formed. The pallet includes a frame 30 having an insulating jacket 40 held together by means of zips 47. The jacket 40 includes a layer of aerogel 42 and 43.

Description

I

Improvements in and relating to transport pallets This invention relates to transport pallets and associated apparatus-referred to herein as a transport pallet arrangement, in particular, but not exclusively for use in keeping transported articles at a temperature different to the ambient temperature.

Transport pallets, for holding or supporting articles to be transported or stored, are well known, and are generally manufactured from wood or metal, for strength. Plastics pallets are known too. Where long distance transport is required, or where air transport is required, then the weight of the pallet is significant.

Articles which need to be kept cool or hot are generally transported in insulated boxes, but these tend to be heavy and require time to be packed and unpacked. When not in use-for example on a return trip, the boxes take up the same space as they do when full.

A known insulated pallet arrangement has been described in GB 2406849, in which a covered pallet is described. The pallet therein described is light weight, but lacks durability and ease of use.

Embodiments of the invention address the problems mentioned above.

According to a first aspect, the invention comprises a transport pallet comprising a load supporting platform supported above the ground in use by a plurality of feet extending downwardly from an underside of the platform, said feet allowing access under said platform, said platform at least, having a platform core of foamed polymer material having a more rigid surface formed by a polymer coating, said coating being applied in liquid form after said core is formed.

Preferably said feet too each have a foot core of said foamed polymer material having said more rigid polymer surface formed from said coating, said foot coating being applied after said foot cores have been formed, said foot coating being applied at the same time as said platform coating.

Preferably said coating are sprayed onto the platform and foot cores, and cures on the cores, following partial absorption of the sprayed liquid coating into the surfaces of the cores.

Preferably said coating is applied over the whole exposed surface area of the cores.

Preferably the material of the platform and feet cores is expanded polypropylene (EPP). This material has been found to possess adequate compressive strength and yet be reasonably lightweight and resilient.

Preferably the coating is an elastomer. More preferably the elastomer is a thermoplastic polyurethane (TPU) resin. TPU when cured has been found to be particularly suitable has a semi-rigid coating for the EPP, which gives a little under load and yet provides a surface which is tough, durable, and resilient.

Preferably the TPU is applied as a resin and has a viscosity when applied to the surface of the cores, which allows said absorption.

Preferably, said pallet further includes a rigid frame supported on said platform, including a plurality of legs which engage with the platform at lower ends of the legs.

Preferably said platform includes sockets into which said legs are removably insertable.

Preferably said sockets are fitted into cut-outs in said upper surface of said platform and in said platform core, and are bonded in place by means of an adhesive or sealant material.

Preferably, said frame comprises two pairs of legs, the legs of each pair being interconnected to form a panel and the legs of each panel being removeably insertable into a corresponding pair of spaced platform sockets.

Preferably the two panels are separably connected together at or adjacent their upper ends by means of one or more frame cross pieces, the or each cross piece being demountable from each of the panels. In this arrangement the panels and cross pieces may be demounted and place flat on the platform for an unladen journey.

The pallet may further include an insulated jacket for fitting over the frame and for removably attaching to the platform.

Preferably the jacket comprises multiple layers of material, including one or more layers of silica aerogel material.

Preferably the jacket comprises: an outer cover layer; said one or more layers of aerogel; one or more layers of fibre material, such as hollow fibres, and one or more layers of metallic, or metallised foil.

Preferably said jacket includes one or more zips extending vertically for accessing articles carried on said platform.

The invention extends to any inventive feature described herein or any combination of said features.

The invention may be put into effect in various ways, one embodiment only being described below, by way of example, with reference to the drawings, wherein: Figure 1 shows a pallet arrangement according to the invention without an insulating jacket; Figure 2a shows the pallet arrangement of Figure 1 having an insulating jacket fitted; and Figure 2b shows some of the insulating jacket material.

Referring to Figure 1, there is shown an insulating pallet arrangement 10, without an insulating jacket, in order to illustrate the components underneath the jacket.

The pallet arrangement 10 includes a pallet 20 manufactured generally from a foamed polymer material, and described in more detail below, and also a frame 30, which, in use, supports an insulating jacket, described below. The pallet 20 has a platform 22 and several feet 24. The feet allow access underneath the platform for forklift tines and the like. Access is gained through the spaces 26 left open by the feet 24. Both the platform 22 and the feet 24 have a foamed polymer core, in this case an expanded polypropylene (EPP) core. The platform 22 is formed from a sheet of EPP to which are adhered the feet 24 manufactured from the same material. The platform and feet are then sprayed with a polymer resin to form a skin which is more rigid than the EPP core. The preferred coating for the EPP is an elastomer polymer, particularly a thermoplastic, such as thermoplastic polyurethane (TPU). This resin coating has been found to provide a suitable skin when cured because it forms a semi-rigid coating which will give a little under load. This is particularly useful because the EPP core deflects resiliently slightly under load also.

The resin coating is applied at a viscosity which allows the resin to be absorbed slightly into the surface layer of the platform and feet cores, and thereby provides very good adhesion between the core and the coating. The resin coating is allowed to cure before the pallet 20 is used.

Although the pallet is describe below in c6njunction with a frame and insulating jacket, it will be understood that the pallet could be used on its own as a lightweight and rigid pallet in place of e.g. wooden or metal pallets having at least three times the weight for the same load carrying capacity.

Figure 1 shows further the frame 30 shown in an assembled condition, but which can be disassembled and laid flat on the empty pallet 20. The frame includes a first panel comprising a pair of legs 32 each inter-connected by stays 34. Lower portions of the legs 32 are inserted into corresponding sockets 28 formed in an upper surface of the platform 22. An identical panel is formed from a pair of legs 33, inter-connected by stays 35 and the identical panel is inserted into sockets 29, only one of which is visible.

The two spaced frame panels are inter-connected at their upper ends by cross pieces 36 which are disassemblable from the two frame panels.

In use the frame 30 is completely demountable to lay flat on the pallet platform 22 for unlaiden transport or storage. When the frame 30 is assembled it has two open sides 37 and 38 which allow easy loading of articles A onto the pallet platform 22.

Netting 39 fitted loosely over the cross pieces 36 provides an area to support cooling blocks, such as ice blocks or other frozen material which keeps the contents of articles A cool during transportation or storage. Equally, means for keeping the articles A warm could be supported on the netting 39.

Referring to Figure 2a a jacket 40 is shown draped over the frame 30.(not shown in figure 2a). The jacket 40 is of a generally rectilinear shape to follow the shape of the frame 30 and includes, at its lower edge, one-half 48 of a hook a burr type fastening which is attachable to a complimentary half 21 of the hook and burr type fastening which in turn is secured around the edge of the platform 22. This hook and burr fastening holds the jacket 40 in place on the frame 30.

In order to allow access to the articles A held on the pallet 20, four zips 47 (only three of which are visible) are provided adjacent each of the legs 32 and 33 of the frame such that unzipped flaps 49 can be formed for inserting or removing articles A onto or from the pallet 20. To reduce heat losses around the zips 47, folded flaps 41 (only one of which is visible) can be provided.

The jacket 40 is manufactured from an outer fabric covering 41, inside which is formed a layer of silica aerogel such as material produced by Aspen Aerogels, Inc. based in the USA. In this case two layers of aerogel 42 and 43 are provided. Inwardly of the aerogel is a layer of hollow fibre material such as polyester fibre or the like. Inwardly of the fibre material is an aluminium foil layer and inwardly of the foil layer is an inner fabric layer 46. The whole layered jacket construction is held together by means of stitching, adhesive, or heat welding, e.g. at the corners or edges of the jacket construction.

Figure 2b shows the construction of the aerogel layers 42 and 43. Since the aerogel is available only in strips, then in this construction the strips are laid in one orientation in one layer and in a transverse orientation in a second layer to reduce heat losses.

Only one embodiment of the invention has been described and illustrated, but it will be readily apparent to the skilled addressee that various modifications, variants, additions or omissions would be possible without departing from the scope of the invention. In particular, the materials used are illustrative only and equivalent materials could be used. For example, frame 30 is preferably manufactured from aluminium or an aluminium alloy to minimise weight, although a polymer composite material could be used in its place. In either instance the frame members are likely to be manufactured from tubular material although at areas where frame members inter-connect, a solid joint could be employed. The materials of the jacket 40 have been described in detail although equivalent materials could be employed.

The overall shape of the pallet arrangement 10 is a rectilinear box although this arrangement lends itself well to the manufacture of custom shapes which could be irregular, or could have curved surfaces, e.g. a cylindrical shape could be manufactured having a circular or rounded pallet 20.

The pallet arrangement 10 has been shown in its erected condition, although it will be understood that the frame 30 when collapsed onto the pallet and with the jacket 40 folded on top will take up far less room than the erected arrangement shown.

Claims

Claims 1. A transport pallet comprising a load supporting platform supported above the ground in use by a plurality of feet extending downwardly from an underside of the platform, said feet allowing access under said platform, said platform at least, having a platform core of foamed polymer material having a more rigid surface formed by a polymer coating, said coating being applied in liquid form after said core is formed.
2. A pallet as claimed in claim 1, wherein said feet too each have a foot core of said foamed polymer material having said more rigid polymer surface formed from said coating, said foot coating being applied after said foot cores have been formed, said foot coating being applied at the same time as said platform C\J coating.
3. A pallet as claimed in claim 2, wherein said coatings are sprayed onto the platform and foot cores, and cures on the cores, following partial absorption of the sprayed liquid coating into the surfaces of the cores.
4. A pallet as claimed in claim 2 or 3, wherein said coating is applied over the whole exposed surface area of the cores.
5. A pallet as claimed in any one of the preceding claims, wherein the material of the platform and feet cores is expanded polypropylene (EPP).
6. A pallet as claimed in any one of the preceding claims, wherein the coating is an elastomer.
7. A pallet as claimed in claim 6, wherein the elastomer is a thermoplastic polyurethane (TPU) resin.
8. A pallet as claimed in claim 7, wherein the TPU is applied as a resin and has a viscosity when applied to the surface of the cores, which allows said absorption.
9. A pallet as claimed in any of the preceding claims, wherein, said pallet further includes a rigid frame supported on said platform, including a plurality of legs which engage with the platform at lower ends of the legs.
10. A pallet as claimed in claim 9, wherein said platform includes sockets into which said legs are removably insertable.
11. A pallet as claimed in claim 10, wherein said sockets are fitted into cut-outs in said upper surface of said platform and in said platform core, and are bonded in place by means of an adhesive or sealant material.
12. A pallet as claimed in any one of claims 9 to 11, wherein, said frame C\J comprises two pairs of legs, the legs of each pair being interconnected to form a panel and the legs of each panel being removeably insertable into a corresponding pair of spaced platform sockets.
13. A pallet as claimed in claim 12, wherein the two panels are separably connected together at or adjacent their upper ends by means of one or more frame cross pieces, the or each cross piece being demountable from each of the panels.
14. A pallet as claimed in any one of claims 9 to 13, wherein the pallet further includes an insulated jacket for fitting over the frame and for removably attaching to the platform.
15. A pallet as claimed in claim 14, wherein the jacket comprises multiple layers of material, including one or more layers of silica aerogel material.
16. A pallet as claimed in claim 15, wherein the jacket comprises: an outer cover layer; said one or more layers of aerogel; one or more layers of fibre material, such as hollow fibres, and one or more layers of metallic, or metallised foil.
17. A pallet as claimed in claim 15 or 16, wherein said jacket includes one or more zips extending vertically for accessing articles carried on said platform. (\J