MXPA06006814A - Corrugated polymeric void board - Google Patents

Abstract

A polymeric void-board is placed between adjacent horizontal layers of bricks to maintain an opening in a lower of the layers. The void-board is fabricated from a first relatively thin planar element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface and a second relatively thin planar element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface. The first and second elements are joined to one another with the ribs of the first element engaging and joined to the second element.

Description

PIPELINE WITH CORRUGATED POLYMERIC HOLES BACKGROUND OF THE INVENTION The present invention relates generally to a polymer board used as a board with holes. More particularly, the present invention relates to a board with corrugated recesses for use in the packaging of brick packs. The bricks are packaged in a common manner as a plurality of individual stacked units (i.e. individual bricks) formed in a three-dimensional package. The package includes one or more bundle strips, corner protectors and a panel with holes, that is placed between two layers of horizontal bricks. In general, the board with holes is placed on a layer of bricks that has no bricks present, for example, forming two holes in the package. Additional layers of bricks are placed on top of the board. The holes, which are centrally arranged in a common manner, are configured to allow the tips of a forklift or similar device to pass inside the package. In the movement of the brick pack, the forklift exerts a force on the bottom of the board, to lift the entire package. In common, the holes are formed by extending through the entire depth of the package. A board with known gaps is formed like a wood veneer. These boards with hollows of wood veneer are often of poor quality and have the tendency to deform. The deformation results in uneven surfaces on which the brick layers are stacked, which in turn can result in package instability. In addition, boards with hollow veneer do not allow clear "separation" of the brick layers (in the depth direction), from the beam, since there is no easy way to separate the bricks and separate or cut the board at the junction of that layer and the rest of the brick package. Another board with holes uses a solid plastic sheet or with ribs. Said gap board is described by Duke et al, United States Patent of North America No. 10 / 803,398, commonly assigned with the present application and incorporated herein by reference. While it has been found that this panel with holes works well in a certain thickness, it requires a greater weight of the material (and therefore cost) than the one desired for said consumable article. When a thinner sheet (and therefore less material) is used, it has been found that the board may not have the desired stiffness. Accordingly, there is a need for a board with holes that is of compatible quality, consistency and strength in order to allow stable stacking of the bricks for package formation without crushing the board. Desirably, said hollowed board is easily separated to separate the brick layers. More desirably, said hollowed board is manufactured or manufactured so that a smaller weight of material is used in order to provide a sufficiently rigid board.

BRIEF DESCRIPTION OF THE INVENTION A board with polymeric voids is configured for placement between adjacent horizontal layers of bricks to maintain an opening in a lower layer of the bricks. The opening is configured for the insertion of a forklift tip in order to transport the brick pack.

The hollowed board is made from a first relatively flat element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface and a second relatively thin flat element having first and second. surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface. The first and second elements are joined to each other with the ribs of the first element that engage and join the second element. In a modality, the ribs of the first element are coupled and are joined to the second element on the first surface. That is, the elements are joined with the ribs of the first element attached to the opposite or planar surface of the second element in a configuration from front to back. Alternately, the ribs of the first element are engaging and attached to the ribs of the second element in a face-to-face (or rib-to-rib) configuration. In both configurations, the ribs of the first and second elements are parallel to each other. The elements are linked together to define hollow spaces between the ribs and the opposite element. This reduces the amount of material needed to make the board with holes. Optionally, the hollowed board can be fabricated with weakened regions formed in the first and second elements generally parallel to the ribs and aligned with each other. This provides a plurality of brittle regions to separate the board. The board may be configured with the ribs at a central distance of about 0.10 inches to about 0.50 inches, and preferably about 0.14 inches. The board can be formed from a polyolefin combination. The polyolefin may be polyethylene and / or polypropylene (and may be about, for example, recycled diapers) and may include a combination with a filler material, such as cellulose fiber material or a thermoplastic elastomer material. The board can be formed from recycled materials, such as recycled diapers. A method for making a polymeric gap board includes the steps of forming a relatively thin first flat element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface, forming a second flat element relatively thin having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface and joining the first and second flat elements together with the ribs of the first element which engages and joins the second element. The first and second elements may be welded together or joined by means of adhesive, and may be joined in a rib-to-rib configuration or a rib-to-back configuration. These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims.

BRIEF DESCRIPTION OF THE DRAWINGS The benefits and advantages of the present invention will become readily apparent to those skilled in the relevant art after review of the following detailed description and accompanying drawings, wherein: Figure 1 is a perspective view of a package of bricks that it has a panel with holes that presents the principles of the present invention placed between horizontal layers of bricks; Figure 2 is a perspective view of a vertical layer of bricks separated from the package of Figure 1; Figure 3 is a final view of a variable mode of the instrument according to the present invention; Figure 4 is an enlarged view, as indicated in Figure 3, showing the rib and the end board profile; Figure 5 is a side view of an alternative embodiment of the board with holes; and Figure 6 is an enlarged view of the board of Figure 5, illustrating the rib and the board profile.

DETAILED DESCRIPTION OF THE INVENTION While the present invention is susceptible to modalities of different forms, they are shown in the drawings and hereinafter will be described in the present non-limiting embodiments, with the understanding that the present description will be considered as an exemplification of the invention and it is not intended to limit the invention to the specific embodiments illustrated. It will be understood that the title of this section of the Specification, that is, "Detailed Description of the Invention" refers to a requirement of the United States Patent Office, does not imply, it will be inferred that it limits the matter in question described herein. Referring now to the figures and in particular to Figure 1, a brick pack 10 is shown with a board-with-holes embodiment 12 in accordance with the principles of the present invention. The package 10 is a three-dimensional stack of individual bricks 14 that form a matrix with a plurality of horizontal layers, for example 16a-16j. The stack 10 therefore defines a length l10, a height h10 and a width w10, which are represented by the axes x, y, z as shown. The package is maintained in the three-dimensional configuration by means of straps 18 which are placed around the package 10. In a common package 10, vertical straps (in the y direction) are placed around the package 10 extending in both directions x, z. Horizontal strips can be, although in general, they are not used. The corner protectors 20 are placed along the corners of the brick pack 10 between the bricks 14 and the strip 18 in order to protect the bricks 14 from damage due to rubbing and accidental shaking. The corner protectors 20 also prevent the strap 18 from failing due, for example, to abrasion. To easily transfect package 10, openings 22 are made by remixing bricks in a predetermined area of the matrix. The openings 22 are configured to allow the insertion of the tips of a forklift. In this way, the tips can be inserted into the openings 22 and the package 10 lifted and transported as desired. To maintain the layer 16d of bricks 14 over the opening 22, the hollowed board 12 is placed between the horizontal layers 16c and 16d of bricks 14, ie, on the layer 16c in which the openings 22 are formed. hollowed-out board 12 is illustrated in Figures 3 and 3A, which show a profile of the board 12. The board 12 is manufactured as an individual wall corrugated member having first and second board elements 24, 26. Each of the elements 24, 26 includes a flat base element 28, 30 each having a thickness t of about 0.20 inches to about 0.80 inches and preferably from about 0.30 inches to about 0.50 inches. A plurality of ribs 32, 34 extends outward from each planar element 28, 30 to a height hr of about 0.20 inches to about 0.80 inches and preferably about 0.30 inches to about 0.50 inches. In a current board 12, the ribs 32, 34 are parallel and are generally of equal height (or distance from their respective planar base element 28, 30). To form the corrugated configuration, the pair of board elements 24, 26 are joined together. As seen in Figures 3 and 3A, in a first embodiment, the elements 24, 26 are joined together in a face-to-face or peak-to-peak configuration. That is, the peaks 36 of the ribs 32 of a board 24 are joined to the peaks 38 of the ribs 34 of the confronting board 26. This produces a pair of board elements 24, 26 separated from one another by means of the ribs of junction 32, 34. This configuration of the board 12 produces a seemingly thick sheet having a plurality of internal ribs 32, 34 connecting the sheets 24, 26 with flat external faces 40, 42. The spaces 44 between the ribs 32, 34 provide a plurality of hollow spaces 44. An alternate embodiment of the hollowed-out board 112 is illustrated in Figures 4 and 4A.

In this embodiment, the board elements 124, 126 are joined in a face-to-face or a board-to-board configuration. Therefore, board 112 appears as a sheet with double stacked ribs. This configuration of the board 112 produces an apparent thick ribbed sheet having a plurality of internal ribs 134 connecting the "lower" board element 126 with the "upper" board element 124 having exposed ribs 132. The spaces defined by the ribs 134 of the "lower" element 126 and face 140 of the "upper" element 124 provide a plurality of hollow spaces 144. The ribs 134 are attached to the face 140 of the element 124 and the face 142 of the element 126 is the "rear" part "Apparent of the board 112. Advantageously, in both modes 12, 112, the strength of the board is preserved even with less material used to manufacture the sheet. This is achieved by providing attached structural shapes to define the board. In one embodiment, the board elements 24, 26, 124, 126 are joined or adhered to each other by welding, adhesive application, extrusion lamination or other processes that will be recognized by those skilled in the art. A preferred method for manufacturing the corrugated gap board is to use ultrasonic welding, for example, in a continuous process in which two sheets in the form of a roll are joined using a guide roll to create the corrugated structure. In this method, a patterned roller (which is a mirror image of the slot pattern, the rib pattern complement, in the rib portion of the extruded sheet) is used to guide the sheet over an ultrasonic anvil (not shown). In a current embodiment, each of the board members 124, 126 has a general thickness t0 (including the thickness of the base member and the height of the ribs) of about 0.40 inches to about 0.80 inches, and more preferably about 0.55 inches. The ribs 32, 34, 132, 134 have a width wr of about 0.20 inches to about 0.60 inches and preferably about 0.25 inches to about 0.35 inches and are spaced apart from the adjacent ribs about 0.10 inches to about 0.50 inches and preferably about 0.10 inches to approximately 0.30 inches in the center.

Optionally, the board with holes 12, 112 can be formed to have one or more weakened regions 48, 148 formed in the flat bases 28, 30, 128, 130. The weakened regions 48, 148 can be made by forming a groove , crease or perforation in the respective bases 28, 30, 128, 130. The weakened regions 48, 148 extend parallel to and between the pins 32, 34, 132, 134. The weakened regions 48, 148 of the upper and lower elements 24, 26, 124, 126 are in the same transverse plane pt with each other and allow the separation of the board 12, 112 (clearly along a "corrugated" or between aligned ribs 32, 34, 132, 134 and within the same hollow spaces 44, 144) after, for example, the bricks forming a vertical layer 50 the package 10 (see Figure 2) are removed. In this way, the remaining board does not extend beyond package 10 as it would be with a solid sheet. Board 12, 112 can be formed from a wide variety of readily available materials. A current board 12, 112 is made from an inexpensive, low melting point resistant polymeric material. It is anticipated that recycled diapers (combinations of polyolefin with various fibrous or particulate fillers) may be used as the material for the board with holes 12, 112. Polypropylene (PP), linear low density polyethylene ( LLDPE), and a filler material such as cellulose fibers or a thermoplastic elastomer material.

Each of the board elements 24, 26, 124, 126, preferably, is an extracted member. The board elements having a density of about 0.7 grams per cubic centimeter (gm / cc) to about 1.3 gm / cc, preferably about 0.85 gm / cc to about 1.15 gm / CC and most preferably about 1 gm / DC. It will be noted that 1 gm / cc equals a specific gravity of about 1.0. It is considered that the ribs 32, 34, 132, 134 are formed in the machine direction of the element 24, 26, 124, 126, for example as the element is extruded, to facilitate manufacture. Said manufacture also results in a high strength board 12, 112. In addition to the improved stability and the "reduced squashing" achieved by the board with holes of the present 12, 112, an additional benefit of the current board is the ability to withdraw a vertical brick layer 50 (removed perpendicular to the direction of fork tip openings 22 as seen in Figure 2), and for retaining board 12, 112 in a clean cut condition by separation along the length of one of the weakened regions 48, 148 to maintain the integrity of the rest of the brick bundle. In the description, the use of the dilemma is intended to include the conjunction. The use of the definite article or indefinite article is not intended to indicate cardinality. In particular, it is intended that a reference to "the" object or "an" object also denote a possible plurality of said objects. All of the patents referred to herein are incorporated herein by reference, whether or not specifically made within the text of this disclosure. From the foregoing, it will be noted that numerous modifications and variations can be made without departing from the spirit and scope of the novel concepts of the present invention. It is understood that no limitation is intended or inferred with respect to the specific embodiments illustrated. It is intended that the description cover by means of the appended claims all those modifications that fall within the scope of said claims.

Claims (24)

1. A polymeric hollow board for placement between adjacent horizontal layers of bricks in order to maintain an opening in a lower layer, the hollowed board comprising: A relatively thin first flat element having first and second surfaces possessing a p lurality of ribs which extend broadly and generally transverse to the first surface; and a second relatively thin flat element having first and second surfaces having a plurality of parallel ribs extending from and generally parallel to the first surface, characterized in that the first and second elements are connected to each other. with the ribs of the first element that attach and join the second element.

2. The panel with polymeric gaps according to claim 1, characterized in that the ribs of the first element are parallel to the ribs of the second element.

3. The panel with polymeric gaps according to claim 2, characterized in that the ribs of the first element are coupled and join the second element in the first surface.

4. The panel with polymeric gaps according to claim 2, characterized in that the ribs of the first element are coupled and join the ribs of the second element.

5. The panel with polymeric gaps according to claim 3, characterized in that the spaces are defined between adjacent blocks of the first element and the second element, and where the spaces are hollow spaces.

6. The panel with polymeric gaps according to claim 4, characterized in that the spaces are defined between adjacent coupling ribs of the first and second elements, and where the spaces are hollow spaces.

The polymeric voided board according to claim 1, which includes weakened regions formed in the first and second elements generally parallel to the ribs and aligned with each other between selected ribs in order to provide a plurality of fragile regions to separate the board.

8. The polymeric gap board according to claim 1, characterized in that a central distance between the first and second element bars is from about 0.10 inches to about 0.20 inches.

9. The panel with polymeric gaps according to claim 8, characterized in that the distance in the center is approximately 0.14 inches.

10. The polymeric gap board according to claim 1, characterized in that the hollowed board is formed from a polyolefin combination.

11. The polymeric gap board according to claim 10, characterized in that the polyolefin is combined with a filling material.

12. The polymeric gap board according to claim 10, characterized in that the polyolefin is polypropylene or polyethylene.

13. The polymeric gap board according to claim 11, characterized in that the filling material is a cellulose fiber material.

14. The polymeric gap board according to claim 11, characterized in that the filling material is a thermoplastic elastomer material.

15. The polymer cork board according to claim 10, characterized in that the polyolefin combination is, in part, recycled material.

16. The polymeric gap board according to claim 15, characterized in that the recycled material SP? recycled diapers.

17. A method for making a board with polymeric holes characterized in that it comprises the steps of: forming a first relatively thin flat element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface; forming a second relatively thin flat element having first and second surfaces having a plurality of parallel ribs extending from and generally transverse to the first surface; and joining the first and second flat elements together with the ribs of the first element that engage and join the second element.

The method according to claim 17, which includes the step of joining the first and second elements to each other with the ribs of the first element joined to the second surface of the second element.

19. The method according to claim 17, which includes the step of joining the first and second elements to each other with the ribs of the first element joined to the ribs of the second element.

20. The method according to claim 1, characterized in that the first and second elements are ultrasonically welded to each other.

The method according to claim 20, characterized in that the first and second elements are joined to each other in a substantially continuous process assembled by a patterned guide roller to place the ribs of the first and second elements in contact with each other. .

22. The method according to claim 1, characterized in that the first and second elements are joined together by means of an adhesive.

23. The method according to claim 1, characterized in that the first and second elements are fermented, in part, from recycled materials.

24. The method according to claim 23, characterized in that the recycled materials are recycled diapers.