HK1226037B - Load bearing structure - Google Patents

Description

load-bearing structure

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/017,079, filed June 25, 2014, entitled “LOAD BEARING STRUCTURE,” which is hereby incorporated by reference in its entirety.

Technical Field

The present invention relates to the general field of load-bearing structures, and in particular to a load-bearing structure for loading, storing and/or transporting goods.

Background Art

A shipping pallet is a well-known, load-bearing, movable platform on which loaded goods are placed. Pallets are typically loaded with different items, such as crates or boxes. Loaded pallets can be moved using a pallet truck or lift.

The adoption of International Standardized Phytosanitary Monitoring (ISPM) 15 for wood packaging material (WPM) requires the kiln-drying of all wood used in shipping crates and pallet platforms (pallets). The United States, in partnership with Mexico and Canada, began implementing ISPM 15 on September 16, 2005. The North American Plant Protection Organization (NAPPO) strategy for strengthening enforcement will be implemented in three phases. Phase 1, from September 16, 2005, to January 31, 2006, required enforcement through account managers and notices affixed to shipments containing non-compliant WPM. Phase 2, from February 1, 2006, to July 4, 2006, required the rejection of non-compliant crates and pallets exported from North America. Enforcement continued through account managers and notices affixed to shipments containing other types of non-compliant WPM. Phase 3, from July 5, 2006, included full enforcement of regulations governing WPM entering North America. Non-compliant WPM will no longer be permitted to enter the United States. The adoption of ISPM-15 reflects growing concern among countries about the potential importation of wood-based transport products containing wood-boring insects, including the Asian Long-horned Beetle, Asian Cerambycid Beetle, Pine Wood Nematode, Pine Wilt Nematode and Anoplophora Glapripwnnis.

As a result, wooden pallet platforms have become unattractive for international shipping of products. Furthermore, wooden surfaces are unhygienic, harboring mold and bacteria in addition to insects. Consequently, wooden crates are generally unsuitable for shipping food and other products requiring hygienic conditions. Furthermore, carbon emissions considerations have led to a greater demand for lighter platforms and crates.

Plastic dunnage platforms or trays are known, see U.S. Patent No. 3,915,089 to Nania and U.S. Patent No. 6,216,608 to Woods et al., both of which are incorporated herein by reference in their entireties. Thermoplastic molded dunnage platforms are known, see, for example, U.S. Patent Nos. 6,786,992, 7,128,797, 7,927,677, 7,611,596, 7,923,087, 8,142,589, 8,163,363, and 7,544,262 to Dummett, which are incorporated herein by reference in their entireties, which disclose the use of thermoplastic sheets to form preformed rigid structures for dunnage platforms.

While the plastic surface of plastic pallets eliminates the hygienic issues associated with wooden pallets, which can become unsanitary due to repeated use, plastic pallets used for food, pharmaceuticals, electronics, and other products requiring hygienic conditions may require that the plastic surface be cleaned and maintained between uses. Furthermore, with most pallets, any defects in the bond between the thermoplastic cover and the core, or between thermoplastic covers, can create areas where moisture, dust, residual product, and bacteria that thrive on moisture, dust, or residual product can hide, grow, and/or accumulate. These areas are often hidden and more difficult to dry or clean than the exposed surface.

Summary of the Invention

The present invention relates to a load-bearing structure having a top side and a bottom side, and a width portion connecting the top side and the bottom side. The load-bearing structure may or may not include multiple supports, and the supports, if present, extend from the bottom side of the load-bearing structure. The load-bearing structure can be composed of a lightweight polymer core covered by or bonded to one or more polymer sheets or films, the edges of the sheets being adhered to the polymer core or another polymer sheet by sealing features, such as those formed using a sealing liquid, a chemical sealing composition, a sealing tape, or by mechanical and/or heat sealing (which may include, for example, ultrasonic heat sealing devices). The seal by the sealing feature is located, for example, at the periphery of the outer edge of the polymer sheet or multiple polymer sheets. For example, the sealing feature is used to seal from about 4 mm to about 12 mm, for example, from about 5 mm to about 10 mm, and for example, from about 5 mm to about 8 mm from the outer edge of the polymer sheet. The remaining bonding area of the polymer sheet, including the outer edge, is substantially bonded by heating and/or pressing during the manufacture of the load-bearing structure.

The shape of the core determines the shape of the load-bearing structure. The core may include a top side and a bottom side, a width portion having a thickness connecting the top and bottom sides, and, in some cases, may or may not include multiple extensions extending from the bottom side of the core. The multiple extensions, if present, form supports for the load-bearing structure. The bottom side and the extensions (if present) may be covered by or bonded to a polymer sheet or film. If only one polymer sheet or film is used, the sheet or film extends to cover the bottom side, the extensions (if present), the entire thickness of the width portion, and at least a portion of the top. If two polymer sheets or films are used to cover the top side, the entire thickness of the width portion, and the bottom side, and may include an overlapping portion of the sheet surrounding the width portion, one sheet or film may extend to cover one side and at least a portion of the thickness of the width portion, while the second sheet or film may cover the remainder of the exposed surface. In most cases, one or more polymer sheets are bonded to the core, or, if one polymer sheet is used, substantially all of the sheet is bonded to the core. This bonding can be achieved by heat and/or pressure.

When the core is covered by a polymer sheet that covers the bottom, the entire thickness of the width portion, and at least a portion of the top side, the outer edge of the polymer sheet on the top side of the core can be securely sealed to a portion of the top surface of the core using a sealing tape, a sealing chemical composition, a sealing liquid, or a mechanical and/or heat seal (which can include, for example, an ultrasonic heat sealer). The sealing tape, sealing liquid, sealing chemical composition, or mechanical and/or heat sealer helps seal the edge portion to the top side of the core, although it may also help seal the rest of the sheet to the bottom of the core, the extension (if present), the entire thickness of the width portion, and a portion of the top surface of the core, but this is not required.

When the core is covered by two polymer sheets, the bottom sheet covers the bottom side of the core, the extension (if present), and at least a portion of the thickness of the width portion of the core, and the top sheet covers the top side of the core and at least a portion of the thickness of the width portion, forming a small overlap of the first and second sheets around the width portion, if desired. At least a portion of the overlap of the first and second sheets (e.g., at least a portion of the overlap near the edge of one or more sheets) can be securely sealed together by a sealing feature, for example, by using a sealing tape, a sealing solvent, a sealing chemical composition, or a mechanical and/or heat seal, and can include, for example, an ultrasonic heat sealer. The sealing tape, sealing solvent, sealing chemical composition, or mechanical and/or heat seal, and can include, for example, an ultrasonic heat sealer, is used to assist in sealing the edges of the overlapping portions of the first and second sheets, and can also assist in sealing the remaining portions of the first and second sheets to the core and to each other.

The edge of the sheet or film may be the outer edge of the sheet or film, or the folded edge, when some hem is present.

The polymer sheet or film can be made of any film-forming material that can impart strength to the core material, such as, but not limited to, high impact polystyrene; polyolefins such as polypropylene, low density polyethylene, high density polyethylene, polyethylene and polypropylene; polycarbonate; acrylonitrile butadiene styrene; polyacrylonitrile; polyphenylene ether; polyphenylene ether alloys with high impact polystyrene (HIPS); polyesters such as PET (polyethylene terephthalate), APET and PETG; lead-free polyvinyl chloride; copolyester/polycarbonate; or copolymers of any of the above polymers; or composite HIPS structures.

Typically, the edges of the load-bearing structure may include a polymer core covered by a polymer sheet or film, as described above. In some embodiments, additional features may be present at intervals or continuously around some of the edges. Such features may include edge protectors, as described below. The edge protectors may be present on the core or on the polymer sheets. When present on the core, the one or more polymer sheets may or may not be bonded or adhered to the edge protectors. If the edge protectors are not bonded or adhered to the one or more polymer sheets, the outer edges of the sheets may be bonded to the edge protectors via sealing features. If the edge protectors are bonded or adhered to the one or more polymer sheets, the outer edges of the sheets may also be bonded to the edge protectors via sealing features.

In these embodiments, the load-bearing structure may be reinforced with edge protectors. Edge protectors may be required to minimize movement when cargo loaded on the structure is restrained by cargo retaining elements, such as straps, tie-downs, cables, ropes, and/or other items to help secure the cargo, particularly during transport. When in use, the bottom edge and the portion of the width portion near the bottom edge of the load-bearing structure typically bear substantially all of the pressure from, for example, straps. In one embodiment, the edge protectors may be present at intervals at predetermined locations on the load-bearing structure where reinforcement may be required. Straps may also be used at these same predetermined locations to help secure the cargo and minimize movement. In another embodiment, the edge protectors may be present continuously around the perimeter of the structure. In another embodiment, the edge protectors may be present continuously or at intervals around the bottom and top edges. According to one embodiment, the edge protectors may have an L-shaped cross-section and may be present at intervals or continuously around at least a portion of the bottom and portions of the width portion of the core, wrapping around a portion of the bottom near the outer edge to wrap around the edge and extending to cover a portion of the width portion near the bottom. According to another embodiment, the edge protector may have a generally C-shaped cross-section with a right-angled edge, and may be spaced or continuous, wrapping around a portion of the bottom side near the outer edge to wrap around the edge and extending to cover the width portion and a portion of the top side near the width portion, appearing around a portion of the bottom, width portion, and top periphery of the core. According to yet another embodiment, the edge protectors may be present in pairs, each having a generally L-shaped cross-section, and may be spaced or continuous, wrapping around a portion of the bottom side near the outer edge to wrap around a portion of the edge and at least a portion of the width portion near the bottom side, and extending to cover a portion of the width portion near the top side and a portion of the top side near the width portion, appearing around a portion of the bottom, width portion, and top periphery of the core.

In one embodiment, edge protectors can be present on the core before the core is covered with the polymer sheet. In one embodiment, the core can be recessed to accommodate the one or more protectors so that the one or more protectors are flush with the rest of the core, allowing the sheet to cover the core with the one or more protectors as if the protectors were not present. In another embodiment, the core can be recessed but not sufficiently to accommodate the full thickness of the one or more protectors, so after covering with the sheet, there may be a slight ridge where the protectors appear. The slight ridge serves as an indicator or guide for positioning the retaining device. In another embodiment, the protectors can be added after the core is covered with the one or more polymer sheets and can be flush with the rest of the load-bearing structure or extend beyond it to form a slight ridge.

When the guard is added before covering the core with the polymer sheet, the core may be indented (as described above), and the guard may not be easily discernible after covering the core with the polymer sheet. In these cases, some guiding features may be present on the load-bearing structure to better locate retention features, such as straps for cargo securement. The guiding features may include markings, slight bumps, protrusions, or ridges to better define the strap position.

The guard may be constructed of any polymeric or metallic material, or a combination thereof, that can be easily molded or cast into the desired shape and that is rigid or substantially rigid or has edges of sufficient strength. In one embodiment, when the guard is present before covering the core with one or more polymeric sheets, the guard may be made of the same material or a material having similar bonding properties as the sheets to help the guard bond to the sheets and/or core at the sheet-to-core bonding temperature. However, as described above, guards made of other materials may still be bonded to the outer edges of the sheets using the sealing feature. In another embodiment, when the guard is added to the load-bearing structure after the one or more sheets are bonded to the core, the guard may be made of any material.

To help hold the guard to the core before or during bonding, a tacky material (e.g., an adhesive or double-sided tape) may also be used. Examples of adhesives may include pressure-sensitive adhesives, such as hot melt pressure-sensitive adhesives or non-hot melt pressure-sensitive adhesives. Examples of double-sided tapes may include double-sided pressure-sensitive adhesive tapes, such as double-sided hot melt pressure-sensitive adhesive tapes or double-sided non-hot melt pressure-sensitive adhesive tapes. The thickness of the adhesive or tape may be very thin so that it does not substantially contribute to the thickness of the edge guard. In some embodiments, the adhesive or tape may be substantially melted during the bonding process.

When the edge protectors are present after the bonding process, a structural adhesive, such as those used in edge sealing described above or below, may be used to secure the edge protectors so that the edge protectors do not fall off or move during and after bundling to secure the cargo.

The guard can be of any thickness as long as it provides the required reinforcement to the edges. Some materials are stiffer than others, so a thinner guard can be sufficiently stiff. The more flexible, thicker components may need to provide sufficient stiffness or strength to withstand the forces of any cargo securing devices, such as straps.

The edge protectors can be manufactured by molding or casting. In one embodiment, the edge protectors can be manufactured in batches and then cut to size. In another embodiment, the edge protectors can be individually manufactured to one or more sizes.

As mentioned above, the edge seals described above may be used regardless of whether the load-bearing structure has edge protection or not.

As mentioned above, the bonding between the core and one or more polymer sheets can be achieved by heating and pressurizing. In some embodiments, the bonding between the core and the thermoplastic sheet and the bonding between the polymer sheets generally include fully bonding the part of the core adjacent to its surface to the part adjacent to the polymer sheet surface, or fully bonding the part of one polymer sheet adjacent to its surface to the part of the second polymer sheet adjacent to its surface, so that any attempt to separate the two parts generally will not result in the complete separation of the parts, but may cause some adhesion failures adjacent to the interface. The bonding process used to make this usually occurs at a relatively high temperature, for example, a temperature that is enough to soften the polymer material. The temperature also depends on the type of polymer used to produce one or more sheets.

When a polymer core is covered by a single polymer sheet, the edge of the polymer sheet is bonded to the surface of the core using heat and pressure. When a core is covered by two polymer films, with the edges of the two films overlapping, the edge of one sheet can be bonded to the surface of the second sheet using heat and pressure. While the bonding process perfectly bonds sheet to core or sheet to sheet, achieving perfect bonding of the edges without adhesive or cohesive failure at the interface can be difficult due to, for example, imperfections in the bonding. Furthermore, more such failures can often occur at the edges, also due to repeated handling of the edges.

When the polymer core is covered by a polymer sheet or film, any unbonded portion of the film can be trimmed after the bonding process. When the core is covered with two polymer films and the edges of the two films overlap, any unbonded portion of the second film can be trimmed and removed. However, general trimming processes may not be effective enough to completely cut off the required unbonded portion. Some parts of the unbonded edge remain on the load-bearing structure. For example, for two polymer films to be bonded at the edge, the unbonded edge portion can be trimmed to as close to the bonding line as possible, but without excessive cost or consideration, it may not be possible to trim off all the unbonded portions. For a film to be bonded to the core, trimming off the unbonded portion is equally difficult. In addition, although the core and the polymer film or the two polymer films bond well, as mentioned above, it may be difficult to completely bond the edge so that trimming is not required. Due to any adhesive or adhesion failure at the interface of the edge, for example, repeated gripping of the edge and/or some defects or adhesion failures in the bonding also usually appear more at the edge.

For hems, the crease is the edge, and although no trimming can be done, some imperfections will still appear in the hem gluing.

When one or more faces are bonded together, the more smooth or flatter these one or more faces are, the more can form more complete bonding with less defect.Under the situation that do not wish to be restricted by theory, although infer that make one or more faces of core and/or polymer sheet evenly as far as possible, these one or more faces of core and/or polymer sheet still can be uneven, and therefore, may have defect in bonding, unless take expensive or special step, so that these one or more faces are smooth.After having finished making core and/or sheet material, the easy way that makes surface smoothness can be that the surface is heated to the temperature that is high enough to make the surface melt, so that molten material can flow, to cover the defect that makes this one and/or multiple faces uneven or not smooth.The processing of high temperature may unnecessarily destroy core and/or sheet material like this.

When such defects or unevenness exist on one or more surfaces of the core or sheet away from the edges, moisture, dust, and/or products left over from previous shipments, as well as bacteria that grow on them, are less likely to accumulate because these surfaces are less exposed to moisture, dust, and/or products left over from previous shipments, as well as bacteria that grow on them. However, any such defects at the edges are more likely to attract moisture, dust, and/or products left over from previous shipments. Bacteria that thrive on moisture, dust, or products left over, as well as moisture, dust, and/or products left over, may be more likely to accumulate around the edges and, once left over, become more difficult to clean off because the accumulation is more or less hidden. This can lead to product contamination or at least cross-contamination, and if the structure is reused for a different shipment (e.g., a different type of food, such as poultry, fresh vegetables, fresh fruit), or even for the same type of product, vigorous decontamination can render the load-bearing surface unusable or dangerous to reuse. Even new load-bearing structures that are not covered or properly stored before use can be susceptible to contamination or infection. Therefore, eliminating contamination or sensing contaminants in these hidden areas is important for goods such as food, medicine, electronics, or any product with exposed surfaces that can be contaminated.

In one exemplary embodiment, a sealing liquid may be used. After the core is covered and bonded to one or more sheets, the liquid may be applied to the interface between the core and the sheets or to the overlapping edges of multiple sheets. The sealing liquid may be any liquid that softens or dissolves the polymer material (or multiple polymer materials) at the interface between the sheet and the core or between multiple sheets to a certain extent to promote strong bonding of the components at the edge. It is desirable to distribute and apply the sealing liquid in a controlled manner or dosage to minimize overflow or dripping or waste of liquid or to minimize excessive dissolution of material at the interface, for example, by using a syringe-type dispenser or other metering device. Regardless of the dispensing device, the front tip of the dispensing device, such as the orifice, has a small cross-section, for example, just large enough for the liquid to be dispensed. The sealing liquid may be active at room temperature. The sealing liquid may be applied before bonding the sheet to the core or another sheet by applying the liquid to the outer edge of one or more sheets or to the core to be sealed.

In another exemplary embodiment, a sealing tape can be used. Before one or more sheets are bonded to the core, the tape can be applied to the edge of one of the one or more sheets or to the core (when using one sheet) so that the high temperature used to bond the one or more sheets can also activate the adhesive used to bond the tape to the core or sheet at the edge. The tape can include a non-sticky or solid heat-activated adhesive (e.g., a hot melt adhesive, a heat-curing adhesive, or a reactive adhesive) on one side and a contact or tacky adhesive on the other side. The contact or tacky adhesive can be covered with a liner before use, and the tape can be tensioned into a roll during storage. When applied to sheets, the liner can be first separated from the contact or tacky adhesive side and bonded to at least a portion of the top surface of the core or the edge of the sheet (if one sheet is used or vice versa), or bonded to at least a portion of one side of the second sheet to be bonded to the first sheet (if two sheets are used or vice versa), or separated therefrom and, essentially simultaneously, the contact or tacky adhesive is applied to one side of the sheet to be bonded to at least a portion of the top surface of the core or the edge of the sheet (if one sheet is used), or to at least a portion of the second sheet to be bonded to the first sheet (if two sheets are used or vice versa), so that the heat-activated adhesive side can be exposed before being bonded to the core or sheet, or the first sheet or the second sheet.

Sealing tape can include a heat-activated adhesive sheet with a contact or tacky adhesive on one side, as described above. In one embodiment, the heat-activated adhesive can be applied to the liner to form a non-tacky adhesive sheet when cooled or dried. On the one hand, the adhesive can be applied to the liner in a solution form, and after the solution evaporates, the adhesive layer can form a non-tacky adhesive sheet. On the other hand, the adhesive can be extrusion-coated to the liner and cooled to a non-tacky adhesive sheet. In another embodiment, the heat-activated adhesive can be any film form that can be cast or extruded and cooled to a non-tacky adhesive sheet, such as a hot melt adhesive.

The heat activated adhesive can be applied on the exposed surface by a contact or tacky adhesive, if the heat activated adhesive is present on the liner, or if there is no liner on either side. The contact or tacky adhesive can be applied by any suitable coating technique, including but not limited to solvent coating, extrusion coating or screen printing with a generally dense array pattern of dots or microdots. The thickness of the contact or tacky adhesive and the heat activated adhesive can vary, but they can usually be thin enough to create an edge that is less noticeable after the edge is joined, which can in turn reduce the tendency to separate. The contact or tacky adhesive and the heat activated adhesive can be selected to form a good bond between the core and the polymer sheet edge or between the edge of the first polymer sheet and the second polymer sheet. The contact or tacky adhesive can be selected for its good adhesive properties to form a good bond between it and the hot melt adhesive layer to reduce adhesive failure on their interface. The adhesive tape can also help to establish a smoother transition at the exposed edge at the interface and can also help to reduce the tendency to separate at the edge. The heat activated adhesive can be any hot melt adhesive, heat curing adhesive, reactive adhesive, etc., that is activated at about the same temperature as the bonding temperature of the polymer layer and the core to form a good bond at the edges, as described above.

In application, separation of the liner from the adhesive layer can be achieved manually by peeling the liner from the core or polymer sheet prior to use, or by using a tape dispenser simultaneously or nearly simultaneously with applying the contact or tacky adhesive to the polymer sheet, which automatically separates the liner from the tacky adhesive during use.

In other embodiments, the tape may be applied to the edge after one or more polymer sheets are bonded so that the tape appears on the outside. In these embodiments, the adhesive may be a pressure-sensitive or heat-sensitive adhesive on only one side, coated on the back.

In other embodiments, one side of the tape may include a heat-activated adhesive while the other side may include a pressure-sensitive and heat-sensitive adhesive such that the tape is secured by pressure prior to heat activation during the bonding process.

In a further exemplary embodiment, a chemical sealing component can be used. When a single polymer sheet is used, the edge of the sheet can be further bonded to the polymer core, or when two polymer sheets are used, bonded to the overlapping area of the first and second layers of a chemical sealing component that can be liquid before use. The chemical component can be a liquid or slurry that can be activated by drying or at the bonding temperature during the bonding process. The slurry can include a mixture of liquids with dispersed particles of the polymer sheet. The liquid chemical sealing component can be used in its natural liquid form, slurry or semi-solid form, or in a treated solid form. The liquid in its natural form can be applied in a manner similar to the sealing liquid described above. The treated slurry can be applied before or after the bonding process or dispensed from a box (such as the plastic squeeze bottle described above, but with a larger opening at its dispensing end) to the edge of the polymer sheet between the core and the sheet. When used before the bonding process, the component can help bond the sheet to the core or the sheet to the sheet, and the liquid and particles can be activated during the bonding process. When the treated chemical sealing component is in solid form, it can include small encapsulated particles that encapsulate the liquid. Application of the solid form may include use of a device for sprinkling the treated chemical composition onto the edges of the core and one or more polymer sheets prior to the bonding process. In either form, the chemical sealing composition may be activated during the bonding process of bonding the polymer core to the one or more polymer sheets, if desired.

The treating material used to form the treated solid form of the chemical seal component is such that it is free-flowing, ie, the treated forms do not adhere to each other but can adhere adequately to a core or sheet, even temporarily prior to a bonding process.

Examples of slurry compositions may include a mixture of the aforementioned sealing liquid mixed with a heat-activated polymer powder, such as the same or similar powdered polymer material used in the manufacture of the polymer sheet. For example, when the polymer sheet is made of high-impact polystyrene, the powder may be powdered polystyrene. The sealing liquid may be relatively non-volatile, such that the liquid does not substantially evaporate prior to the bonding process between the sheet and the core and/or between the sheets.

As described in more detail below, the chemical sealing composition may also include a self-recovering and/or self-healing composition. The self-recovering and/or self-healing composition may also be present in any other sealing feature.

In yet another exemplary embodiment, the edges can be sealed using mechanical and/or heat sealing devices, such as ultrasonic heat sealing devices. For example, ultrasonic energy can be generated using, for example, an ultrasonic horn and/or an ultrasonic welder. The ultrasonic energy level can be selected to affect but not distort the edges during bonding.

In some embodiments, as the first and second polymer sheets are bonded to the polymer core, they can be partially folded over each other and the folded areas can be subjected to heat, pressure, and/or vacuum to create a sealed bond. Excess material of the polymer sheets can be trimmed off.

In one embodiment, the polymer sheet or film layer may include an antimicrobial agent with a certain surface activity. In another embodiment, an antimicrobial coating with a certain surface activity may be applied to at least one of the exposed surfaces of the load-bearing structure, regardless of whether the surface is covered by the sheet or film layer. The antimicrobial agent may be in powder or liquid form. In either form, the antimicrobial agent should be able to withstand the bonding temperature without degradation or loss of its performance.

According to one embodiment, the polymer film or sheet layer covering the core may have antimicrobial properties. In one aspect, the polymer layer (e.g., a high-impact polymer sheet) may cover the bottom surface, the entire thickness of the width portion, and a portion of the top surface of the core. In another aspect, the polymer film or sheet layer (e.g., a high-impact polymer sheet with antimicrobial properties) may cover the top and bottom portions of the core and substantially the entire thickness of the width portion.

In one exemplary embodiment, at least one antimicrobial agent with a certain surface activity may be incorporated into the material used to manufacture the sheet. The antimicrobial agent may be in powder or liquid form. In another exemplary embodiment, the at least one antimicrobial agent with a certain surface activity may be applied to the exposed surface or surfaces of the load-bearing structure, regardless of whether such surface is covered by the sheet or film layer. The antimicrobial agent may be in powder or liquid form. In either form, the antimicrobial agent should be able to withstand the bonding temperature of the one or more sheets to the core without degrading or losing its performance.

In another embodiment, the porous surface, which may be a porous plate substrate as described above, or a polymer core (e.g., a foamed polymer core or a polyurethane core), may be covered by a polymer sheet, with a portion of the top surface of the core exposed. The polymer sheet may be impregnated with an aqueous antimicrobial composition, which may be in the form of an emulsion or dispersion, and at least one substantially non-leaching antimicrobial composition that is substantially free of environmentally harmful materials. After impregnation with the antimicrobial composition, the porous surface may or may not be further coated throughout or protected with a film layer.

In another embodiment, the porous surface, which may be a porous plate substrate, may be impregnated with an aqueous antimicrobial composition having at least one polymeric carrier, which may be in the form of an emulsion or dispersion, and at least one substantially non-leaching surface-active antimicrobial composition that is substantially free of environmentally harmful materials.

In another embodiment, a non-porous plate substrate may be coated with an aqueous antimicrobial composition having at least one polymeric carrier that may be in the form of an emulsion or dispersion and at least one substantially non-leaching antimicrobial composition that is substantially free of environmentally harmful materials.

For load-bearing structures having a thermoplastic sheet on a core, the exposed surface can be porous, as described above. The porous material can be impregnated with an aqueous antimicrobial composition, which itself can form a film to render the surface non-porous, as also described above.

In some embodiments, the surface of the porous material impregnated with the antimicrobial composition can be non-porous after drying or standing, and can function as if it had been coated or covered with the thermoplastic sheet or protective sheet described above.

The same emulsion or dispersion described above can also be applied to the exposed surface of a load-bearing structure having a core having two thermoplastic sheets running through it when the exposed surface is non-porous.

In any of the above disclosed embodiments, the antimicrobial agent may be added after the heat sealing process. In the embodiment where heat sealing is achieved after the antimicrobial agent is added, the antimicrobial agent used can maintain or not lose its antimicrobial properties during the bonding process.

In any of the embodiments having antimicrobial properties, edge bonding may be performed before or after coating with the antimicrobial layer.

Antimicrobial agents can help minimize the accumulation of bacteria on the load-bearing structure. However, edge sealing and antimicrobial agents can help minimize the accumulation of dust, dirt or bacteria.

In other embodiments, the core may include a structural metal mesh to resist puncture of the surface.

In another embodiment, the supporting structure has antibacterial properties and/or puncture-resistant properties, and may also have flame-retardant properties and/or ultraviolet light protection properties.

In one embodiment of the present invention, the load-bearing structure can be a dunnage platform having a top surface and a bottom surface separated from each other by a width portion having a thickness. The platform can be generally square or rectangular in shape. A box can be assembled from multiple load-bearing structures (e.g., dunnage platforms), each having a lightweight polymer core and a high-impact polymer sheet substantially covering the core, as described above. The dunnage platforms that can be used to assemble into a box can include interlocking features that mate together to form the box.

The edges of the load-bearing structure of the box may be joined by sealing tape, a sealing chemical composition, a sealing liquid, or mechanical and/or heat sealing (eg, using ultrasonic sealing devices), as described above.

In one embodiment, when the load-bearing structure described above can be assembled into a box having a bottom, a top, and walls, the expansion can occur at one or more of the bottom, the top, and the walls.

The sheet or film layer covering the core of each box wall, top and bottom may also include antimicrobial properties as described above. The wall may or may not include a support member. In an exemplary embodiment, at least one antimicrobial agent with a certain surface activity may be added to the material used to prepare the polymer sheet or film layer (e.g., a high-impact polymer sheet). The antimicrobial agent may be in powder form or liquid form. In another exemplary embodiment, at least one antimicrobial agent with a certain surface activity may be coated on the exposed surface or surface of the sheet. The antimicrobial agent may be in powder form or liquid form.

In the above form, the antimicrobial agent can maintain its properties during the bonding process.

In some aspects, the lightweight, strong box assembled from the plurality of movable load-bearing structures described above may also be puncture-resistant and/or flame-retardant and/or UV-protective, with or without antimicrobial properties.

One of the load-bearing structure or the dunnage platform of the box may also have a plurality of feet extending from the bottom surface of the structure, as described above.

In another embodiment of the present invention, the load-bearing structure can be in the form of a generally L-shaped cross-section having an inner surface and an outer surface connected by a width portion, the width portion having a thickness. The surface of the polymer core can be partially or completely covered by a polymer sheet. The edges of one or more sheets can be sealed using tape, a sealing fluid, a sealing chemical composition, or mechanical and/or heat sealing, which can include the use of ultrasonic heat sealing devices, as described above.

In one embodiment, the box may include two complete or mirrored generally L-shaped cross-sectional halves, each having at least two walls and a bottom or top member, each member having corresponding interlocking features to fit together to enclose the box with a closed enclosure. The box has a footprint no larger than one of the generally L-shaped cross-sectional halves.

The L-shaped load-bearing structure or dunnage platform of the box may also have a plurality of legs extending from the bottom surface of the structure.

In another embodiment of the present invention, the load-bearing structure can be in the form of a clamshell having an inner surface and an outer surface connected by a width portion, the width portion having a thickness. The surface of the polymer core can be partially or completely covered by a polymer sheet. The edges of one or more sheets can be sealed using tape, a sealing fluid, a sealing chemical composition, or mechanical and/or heat sealing, which can include the use of ultrasonic heat sealing devices, as described above.

The box may comprise two mirror-image clamshell halves, each having at least one wall and a bottom or top member, each half having corresponding interlocking features to fit together to enclose the box, for example, having a closed enclosure. The box may also comprise a plurality of supports.

In any of the above embodiments, the load-bearing structure can be a generally L-shaped cross-section or clamshell-shaped half having at least two walls and a bottom or top member. The box can be assembled from identical or mirror-image identical components, with each half having corresponding interlocking features to fit together to enclose the box with a closed outer shell. The edges of the halves can also be sealed, as described above. In one aspect, the footprint of the removable or foldable box does not exceed the footprint of each L-shaped or clamshell half. In another aspect, the footprint of the removable or foldable box is greater than the footprint of each L-shaped or clamshell half.

In one embodiment, each half can be covered by an inner lightweight core covered by at least one reinforcing film or sheet layer. In one aspect, the reinforcing sheet or film layer can include antimicrobial properties, as described above. In another embodiment, the core can include antimicrobial properties, as described above.

In some embodiments, a structural metal mesh may be inserted into the core to resist puncture on the surface.The box may also have flame retardant properties and/or UV protection properties.

The load-bearing structures of the present invention can be used to load, store or transport products that either cannot withstand such contamination or cross-contamination, are susceptible to damage, or have an undesirable perception of non-cleanliness. The present invention also relates to load-bearing structures that can be used directly in clean rooms used to manufacture electronic parts, microelectronic devices, pharmaceuticals and medicines, food products such as snacks, or similar products that need to be kept clean from dust, dirt or bacteria. Goods can be loaded directly after manufacturing without the additional step of transferring the goods from the clean room to the load-bearing structure, thereby reducing steps, saving time, reducing the risk of manual or mechanical or contamination or damage. Edge sealing further increases the cleanliness of the load-bearing structure.

According to one embodiment, a box may include an outer shell with an integral interior compartment. According to another embodiment, a box may include an outer shell with multiple interior compartments. In one aspect, the interior may include dividers molded into the sides of the component frame. In another aspect, dividers may be added to the box to form separate compartments. Channels or recesses may be present or molded into the box's components to allow for configuration of external dividers to adjust the size of the compartments.

According to one embodiment, features may be present or formed in components of the box for arranging cargo or other components for more securely placing cargo. According to another embodiment, channels or recesses may be used to locate the features.

In one aspect, the box can be sized and shaped to accommodate the goods. In another aspect, the goods can be contained in their own packaging and then inserted into the box. In yet another aspect, features can be located in the box to help contain the goods.

The invention also relates to a box for transporting and/or storing goods, the climate inside the box being controllable.

According to the present invention, a polymer core, such as a closed-cell foam core, such as an expanded polystyrene core, has a region adjacent to its surface that is bonded to a high-impact polymer sheet (e.g., a polystyrene sheet) by heat and pressure. In one exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be added to the material used to make the sheet. The antimicrobial agent may be in powder form or liquid form. In another exemplary embodiment, at least one antimicrobial agent having a certain surface activity may be applied to at least one of the exposed surfaces of the sheet. The antimicrobial agent may be in powder form or liquid form.

The load-bearing structure may also include multiple supports. As mentioned above, these supports typically separate the bottom surface of the load-bearing structure from the ground and/or other supporting surfaces. The supports may also be spaced apart from one another, for example, so that the load-bearing device can be maneuvered into the spaces between the supports using a forklift and/or other moving machinery. In some embodiments, bars, bridges, and/or other connectors, such as connecting multiple supports, may also be included to generally increase the strength and/or rigidity of the bottom. For example, the bridges may be constructed from wood, metal, and/or various plastic materials (including polyolefins, polyesters, lead-free PVC, etc.), or any of the aforementioned suitable polymer sheet materials. In some embodiments, the bars or bridges are made from HIPS (high-impact polystyrene) using an extrusion molding process. Furthermore, the bridges can be configured so that each spans two or more supports in a row and can be secured to the ends of the supports to interconnect them. For example, the bridges can be attached using a suitable adhesive. Furthermore, the bottom of the supports used to secure the bridges may include recesses for positioning the bridges so that they do not protrude from the bottom of the supports but are flush with the bottom of the supports.

Strips or bridges can extend between adjacent supports. In one embodiment, the bridges can be a plurality of wear-resistant components secured to the underside of at least some of the supports and adapted to bear against a substrate, upon which a load-bearing structure can be disposed. Alternatively, the strips or bridges can be configured such that each spans two or more supports in a row and can be secured to each support wall to interconnect them uniformly. For example, the strips or bridges can be secured to adjacent ends using a suitable adhesive.

The load-bearing structure may also include anti-slip components or further strengthening features. For example, the bottom surface of the load-bearing structure, or the bottom (if it is used as a component of the box), and/or the support members may also include ridges, rib reinforcements, and/or other surface reinforcements, for example, to help increase the strength and/or rigidity of the bottom structure, especially the strength and/or rigidity under load. Some improvements may also help to reduce any unintended sliding of the box while it is at rest. In one aspect, the improvement may roughen the bottom surface to reduce sliding. It is also believed that the ability of the support members and/or the bottom to resist compressive loads may be greatly improved if each wall includes a plurality of ribs extending generally longitudinally.

Other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments as illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

1 and 1a are perspective views of the top side of a core of a load-bearing structure according to the present invention with and without extensions or supports, respectively;

2 and 2a are perspective views showing the bottom side of the core shown in FIG1 and 1a, respectively;

3 shows a line drawing of a loaded cargo tool dunnage platform with half a housing placed on the cargo tool dunnage platform in accordance with an embodiment of the present invention;

FIG3A shows a line drawing of a cargo tool dunnage platform with phase change material boxes positioned in pockets;

FIG4 shows an embodiment of the load-bearing structure of the present invention;

4A shows a line drawing of an unloaded cargo tool dunnage platform with a half shell positioned on the cargo tool dunnage platform in accordance with an embodiment of the present invention;

4B shows a line drawing of a closed cargo tool dunnage platform having two housing halves placed on the cargo tool dunnage platform in accordance with an embodiment of the present invention;

5-7 illustrate various embodiments of the box of the present invention during assembly;

FIG8 shows an embodiment of a box according to the present invention during assembly, illustrating interconnecting features;

8A-8E show various embodiments of a box according to the present invention, illustrating interconnecting features during assembly;

FIG9 shows a line drawing of an unloaded cargo tool dunnage platform with a half shell positioned on the cargo tool dunnage platform according to another embodiment of the present invention;

FIG10 shows an L-shaped half shell of an embodiment of a box according to the present invention, which has the function of positioning goods or partitioning;

FIG10A shows a full view of the inner bottom of an embodiment of a box according to the present invention, which has the function of positioning goods or partitioning;

FIG11 shows a fully assembled box according to an embodiment of the present invention;

FIG11A shows an L-shaped half shell of an embodiment of a box according to the present invention, which has the function of positioning cargo;

Figures 12, 12a-12g illustrate an embodiment of a load-bearing structure according to the present invention having at least one polymer sheet bonded thereto and sealing features for the edges of the polymer sheet;

12h-12m illustrate an embodiment of a load-bearing structure according to the present invention having two polymer sheets bonded thereto and folded sealing features for the edges of the polymer sheets;

13 and 13a illustrate a method of sealing a polymer sheet to a polymer core using a sealing liquid in accordance with an embodiment of the present invention;

Figures 14, 14a and 14a-1 show an embodiment of the present invention in which tape is used as a sealing feature;

Figures 14b and 14c illustrate the application of tape to the edges of a polymer sheet bonded to a polymeric core of a load-bearing structure in accordance with an embodiment of the present invention;

FIG14 d shows a side-coated tape at the edge of a polymer sheet bonded to a polymeric core of a load-bearing structure in accordance with an embodiment of the present invention;

FIG14e shows the edge of a single polymer sheet bonded to the polymeric core of a load-bearing structure in accordance with an embodiment of the present invention;

15-15h illustrate an embodiment of a load-bearing structure without extensions or supports according to the present invention, having sealing features of at least one polymer sheet and polymer sheet edge in combination;

Figures 16 and 16a show an embodiment of a box with a tongue and groove seam according to an embodiment of the present invention;

Figures 17 and 17a show the bottom of the embodiment of the box shown in Figures 16 and 16a;

Figures 18, 18a and 18e show the wall panels of the embodiment of the box shown in Figures 16 and 16a;

Figures 18b, 18c and 18d respectively show a wall panel connected to a top panel, another wall panel and a bottom panel in an embodiment of the present invention;

Figures 19 and 19a show the top panel of the embodiment of the box shown in Figure 16;

FIG20 shows the assembly of the embodiment of the box shown in FIG16;

Figures 21 and 21a-e show embodiments of the base of the present invention having different extensions or supports;

Figures 22, 22a and 22b illustrate fully formed or connected wall panels in a generally L-shaped configuration for connection to top and bottom panels in accordance with an embodiment of the present invention;

Figures 23, 23a and 23b show a pair of fully formed or connected wall panels in a generally L-shaped configuration, one of which is fully formed or connected to the top panel and the other is fully formed or connected to the bottom panel, in accordance with another embodiment of the present invention;

24 and 24a-24c illustrate a load-bearing structure having a depression in accordance with an embodiment of the present invention, wherein the depression is configured to accommodate an edge protector to accommodate a cargo support;

FIG. 24 d shows a load-bearing structure having an extension or support member and a recess for accommodating an edge protector without a guide groove in accordance with an embodiment of the present invention;

FIG. 24 e shows a load-bearing structure having a recess for receiving an edge protector, without a guide slot or extension or support member, in an embodiment of the present invention;

FIG25 shows a load-bearing structure with edge protectors and guide grooves according to an embodiment of the present invention;

25a, 25b and 25c are partial cross-sectional views of a load-bearing structure with an example of an edge protector according to an embodiment of the present invention, wherein the edge protector is seated in a recess;

Figures 26 and 26a respectively show examples of L-shaped and C-shaped edge protectors in accordance with an embodiment of the present invention; and

27 and 27a illustrate a load-bearing structure having edge protectors with guide features in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

The following detailed description is intended to describe the systems, devices, and methods provided according to aspects of the present invention, as exemplified below, and is not intended to represent the only way in which the present invention may be prepared or used. Rather, it should be understood that the same or equivalent functions and components may be accomplished through different embodiments, and such different embodiments are intended to be included within the spirit and scope of the present invention. Furthermore, unless otherwise specified, all technical and scientific terms used herein have the same meanings as commonly understood by one skilled in the art to which the present invention pertains. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, only exemplary methods, devices, and materials are described below. All publications mentioned herein are incorporated herein by reference for the purpose of describing and disclosing, for example, designs and methodologies described in such publications that may be used in conjunction with the present invention. Publications listed or discussed above, below, and throughout the text are provided only to the extent that their publication dates predate the filing date of the present application. No admission is made herein that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

In FIG1 , a foamed polymer core 10a (e.g., a polystyrene core) is in the form of a generally rectangular slab having a width portion 12 ( FIG1 ) having a thickness 14a that can be of any size, for example, approximately 1 3/4 inches to 2 inches (about 4.5 centimeters to about 5 centimeters). The core 10a can have a smooth top side 16a that can be partially or completely covered with a polymer layer, for example, a high-impact polymer sheet 67 such as a high-impact polystyrene board, which can be approximately 4 feet long and 40 inches wide. The smooth top side 16a can generally transition to the width portion 12 at its periphery having an edge 12a. As shown in FIG2 , the bottom side 18a of the core 10a can include one or more extensions or supports 20-28, although most embodiments may not include multiple extensions or supports. If present, these extensions or supports can extend from the bottom side 18a by a length of, for example, about 4 to 6 inches (about 10 centimeters to about 20 centimeters). 2 , rim 12a is adjacent to spaces 42, 44, 46, 48 on bottom side 18a. These marginal spaces 42, 44, 46, 48 separate extensions or supports 26-28, extensions or supports 20, 23, 26, extensions or supports 20-22, and extensions or supports 22, 25, 28, respectively, from rim 12a.

Figures 1a and 2a are similar embodiments to Figures 1 and 2, but without the multiple extensions or supports.

The load-bearing structure 10 also has a width portion 12 having a thickness 14, which is the combined thickness of the core 10a and the panels 67. Cargo may be loaded onto the top side 16a of the load-bearing structure 10. The cargo may be fragile or non-perishable and may include fresh vegetables and fruits, poultry and meat products, medicines and pharmaceuticals, electronic components and equipment, and the like.

Moisture, dust, and/or product residues, and bacteria that grow on them, can lead to product contamination or at least cross-contamination, and can also render a load-bearing structure unusable or dangerous if it is reused for different goods than the previous one (e.g., a different food type such as poultry, fresh vegetables, and fresh fruit, or even the same product type), without achieving the same robust decontamination effect. Even if the load-bearing structure is remanufactured, dust and/or moisture, and bacteria that grow on them, can lead to contamination of the goods loaded on it. Dust and/or moisture, and bacteria that grow on them, can easily hide, grow, or accumulate in the interfaces between the layers of material if there are defective connections and/or bonds between the layers.

Typically, when bonding the polymer film to the polymer core normally, heat and pressure are applied so that the portion of the polymer core proximate the surface of bottom side 18 a forms a substantially reinforced composite with the portion of polymer sheet 67 proximate the surface of the bottom side of sheet 67. In addition, a portion of the polymer core proximate edge 12 and in close relationship with bottom side 18 a is bonded to a portion of polymer sheet 67.

However, even if the bond between the bulk of the polymer core and the polymer sheet is strong enough to produce a reinforced load-bearing structure with and without defects, there is still a need to improve the bond between the periphery of the polymer sheet and the polymer core in order to minimize or eliminate any defects in which dust, dirt and/or moisture often hide, grow or accumulate, and when there are connection and/or bonding defects between layers, they often hide, grow or accumulate in the seams between layers of material.

As shown in Figures 1, 1a, 2 or 2a, the support structure or platform 10 may include a lightweight polymer core 10a covered by a polymer sheet or two polymer sheets 67 as described above, and the interface between a polymer sheet 67 or 68 (as shown in Figures 12 and 15) and the surface of the core, or the interface of the edge formed by overlapping and/or abutting one polymer sheet to another polymer sheet can be sealed using sealing features, such as sealing liquids, heat-activated adhesives, sealing compounds, or mechanical and/or heat seals, and may include ultrasonic sealing equipment, so as to minimize or eliminate areas where moisture, dust and/or residual product and bacteria that grow on dust or moisture may hide, grow and/or accumulate.

A sealing feature is optionally applied near the outer edge of one or more polymer sheets, for example, polymer sheet 67 or polymer sheets 67, 68. While a larger portion can be sealed, it is sufficient to seal a smaller portion of the outer edge with the sealing feature. The sealing feature is used to seal, for example, from about 4 mm to about 12 mm from the edge of the polymer sheet, more preferably from about 5 mm to about 10 mm from the edge of the polymer sheet, and even more preferably from about 5 mm to about 8 mm from the edge of the polymer sheet. As described above, during the process of manufacturing the load-bearing structure, heat and/or pressure are applied to bond the remaining bonding areas of the polymer sheets, including the outer edges. In Figures 13 and 13a, for example, the sealing feature is present approximately 7 mm from the outer edge of the second sheet 68.

Examples of heat activated adhesives include, but are not limited to, adhesives comprising ethylene alpha olefin interpolymers, such as those disclosed in U.S. Patents 6,319,979, 6,107,430, and 7,199,180; metallocene based adhesives, including adhesives comprising substantially linear ethylene/1-octene copolymers, which are commercially available from The Dow Chemical Company, and adhesives disclosed in U.S. Patents 8,222,336 and 8,163,833; metallocene hot melt adhesives including those disclosed in U.S. Patent 8,476,359; propylene based hot melt adhesives including those containing non-metallocene, metal-centered, heteroaryl ligand-catalyzed propylene with and ethylene copolymer adhesives; reactive hot melt adhesives such as disclosed in U.S. Patent 8,507,604; heat-activated hot melt adhesives including adhesives disclosed in U.S. Patents 8,475,046 and 8,240,915; adhesives containing metallocene complexes as well as non-metallocene complex polymers such as disclosed in U.S. Patent 8,475,621; adhesives containing ethylene alpha-olefins such as disclosed in U.S. Patent 6,107,430; hot melt adhesives containing bulk polymers such as disclosed in U.S. Patent 8,501,869; and polyolefin adhesives such as disclosed in U.S. Patents 8,283,400 and 8,242,198, all of which are hereby incorporated by reference in their entirety.

The sealing liquid may be any solvent which slightly dissolves the core and/or polymer sheet during the sealing process, provided the liquid is non-toxic. It is also desirable that the liquid has a moderately high solubility coefficient for the core and/or polymer sheet so that a small amount of liquid is sufficient. The liquid may be slightly volatile or relatively non-volatile at room temperature. Examples may include chloride solvents such as tetrachloroethylene; or some cyanoacrylate adhesive compounds. As previously described, the liquid may be applied to the edge of the polymer sheet and the core or the interface between two polymer sheets by a dispensing device. Figure 13 shows an example. The application may be done after the bonding process, particularly if the liquid is relatively volatile at room temperature and dries relatively quickly.

The sealing compound may comprise any relatively nonvolatile liquid and may be in liquid form, processed form such as a semi-liquid composition comprising a mixture or suspension of liquid and solid particles, solid form such as any liquid adhesive or encapsulated sealing composition.

Processed sealing compounds, such as suspensions, can have lower volatility than pure solvents or even compounds, allowing them to be applied in addition to being dispensed from a dispenser such as a can. While similar to a squeeze bottle or syringe as described above, the can has a larger opening at its dispensing tip, which can be placed on any edge of the polymer sheet before or after the bonding process between the core and the panel, depending on the activation temperature of the composition. In some embodiments, the suspension composition can include a mixture of sealing liquids, such as those described above, with powdered polymer materials that are the same or similar to those used in the manufacture of the polymer sheet. For example, when the polymer sheet is made of high-impact polystyrene (HIPS), the powder can include powdered polystyrene. The sealing liquid can be relatively non-volatile, so that it is substantially non-evaporating before the panel with the core and/or the bonding process between the panels. In one example, a solvent, such as tetrachloroethylene solvent, can be mixed with a solid to form a suspension that can be applied as described above. This suspension can be dried after application, and, for example, particles can be added to aid in sealing if heat activation occurs at a later stage.

When the treated chemical sealing composition is in solid form, which may include small encapsulated particles that encapsulate within them a solvent, suspension, or any liquid of the sealing composition, pressure or heat and pressure may be applied for activation to crush or melt the capsules and release the adhesive.

Figures 12 and 12a-f illustrate portions of an example load-bearing structure 10 with extensions or supports, as described and shown in Figures 1 and 2, and Figures 15-15h illustrate portions of an example load-bearing structure 10 without extensions or supports, such as those described and shown in Figures 1a and 2a, or other portions not described above, which may also include a lightweight polymeric core 10a having a width portion 12. The load-bearing structure 10 may also include at least one polymer sheet, such as polymer sheets 67, 68, as shown, as described above, and may also include at least one sealing feature 70 or 80 for sealing the edges of polymer sheets 67, 68 to each other and/or to the polymeric core 10a, as illustrated. Generally, the sealing of the polymer sheets to the polymeric core and/or between the polymer sheets may be performed in the same and/or similar manner as any of the load-bearing structures and/or boxes described herein.

Figures 12 and 15 illustrate an embodiment of a load-bearing structure 10 having a first polymer sheet 67 and a second polymer sheet 68, wherein the first and second polymer sheets 67, 68 can be joined at an abutment 69. Abutment 69 can generally be formed by edges 67c, 68c of the polymer sheets 67, 68, respectively, and can be a smooth interface or can include gaps and/or irregularities, for example, resulting from the manufacturing and/or joining process of bonding the polymer sheets 67, 68 to the polymer core 10a, as described above. As shown in Figures 12 and 15, in some embodiments, a sealing feature 80 can be utilized to seal and/or cover the abutment 69 between the two polymer sheets 67, 68. Sealing feature 80 can generally cover and/or fill any gaps and/or irregularities present at the interface and can also generally extend a given amount across each polymer sheet 67, 68, for example, to form a more robust and/or durable seal. Generally speaking, a sealing feature covering the junction 69, such as the sealing feature 80 shown in Figures 12 and 15, can be applied after the polymer sheets 67, 68 are bonded to the polymeric core 10, because the sealing feature 80 is located on top of the polymer sheets 67, 68. Sealing features suitable for such an application may include any of the sealing features described above, for example, a sealing tape that may include an adhesive surface on one side of the tape.

The sealing feature may also be located between the panels 67, 68 at the edges, similar to the sealing feature 70 shown in Figures 12e and 15e. The sealing feature 70 may be any of the sealing features described above, for example, a double-sided adhesive sealing tape, a sealing liquid, a sealing chemical composition, a mechanical seal that may include an ultrasonic seal, and/or a heat seal.

In other embodiments, as shown in Figures 12a, 12b, 15a, and 15b, the load-bearing structure 10 can include a single polymer sheet 67, wherein the polymer sheet 67 can extend around and wrap around the entire thickness 14a (shown in Figures 1 and 1a) of the width portion 12 of the polymeric core 10a, or can even extend to some portion of the top surface 16 of the core as shown in Figures 12a and 15a, or abut the width portion 12 of the polymeric core 10a as shown in Figures 12b and 15b. The edge 67a or 67b of the polymer sheet 67 can be sealed to the polymeric core 10a by a sealing feature 70, wherein the sealing feature 70 can be placed between the polymer sheet 67 and the polymeric core 10a as shown in Figures 12a, 12b, 15a, and 15b. For example, the sealing feature 70 can be applied to the polymeric core 10a before bonding the polymer sheet 67. As another example, the sealing feature 70 can also be applied to the polymer sheet 67 and bonded to the polymeric core 10a at the same time as the polymer sheet 67. In another embodiment, the sealing feature 70 can be applied between the edges 67a, 67b of the polymer sheet 67 and the polymeric core 10a after the polymer sheet 67 has been bonded to the polymeric core 10a. For example, the sealing feature 70 can include a sealing liquid, a chemical sealing composition, an adhesive tape, etc. as described above, and can be inserted, injected, pressed, and/or otherwise placed between the polymer sheet 67 and the polymeric core 10a. In another example, the sealing feature can be provided by heat sealing, or can be an ultrasonic sealing device.

In still other embodiments, as shown in Figures 12c, 12d, 15c, and 15d, a load-bearing structure 10 having a single polymer sheet 67 can be abutted at the width portion 12 of the polymeric core 10a, as shown in Figures 12c and 15c, or wrapped around the width portion 12 of the polymeric core 10a, as shown in Figures 12d and 15d. The edges 67a, 67b of the polymer sheet 67 in Figures 12d and 12c, or 15d and 15c, respectively, can be a smooth interface, or they can include some gaps and/or irregularities, for example, resulting from the manufacturing and/or connection process of bonding the polymer sheet 67 to the polymeric core 10a. Thereafter, a sealing feature 80 can be used to seal and/or cover the edges 67a, 67b of the polymer sheet 67 and extend over the polymeric core 10a. The sealing feature 80 can generally cover and/or fill any gaps and/or bumps that may exist at the interface, and can also generally extend a given amount above the polymer sheet 67, for example, to create a stronger and/or more durable seal. Generally speaking, a sealing feature that covers the edge of the polymer sheet and a portion of the polymeric core 10a, such as the sealing features 80 shown in Figures 12c, 12d, 15c, and 15d, can be applied after the polymer sheet 67 is bonded to the polymeric core 10, as the sealing feature 80 is located on top of the polymer sheet 67. The sealing feature can include any of the sealing features described above, such as, for example, a single-sided adhesive tape.

Figures 12e and 15e illustrate an embodiment of a load-bearing structure 10 having a first polymer sheet 67 and a second polymer sheet 68, wherein the first and second polymer sheets 67, 68 can be joined at a junction 69. Junction 69 can generally be formed by edges 67c, 68c of the polymer sheets 67, 68, respectively, and can be a smooth interface, or it can include some gaps and/or irregularities, for example, resulting from the manufacturing and/or joining process of the polymer sheets 67, 68 to the polymeric core 10a. In some embodiments, as shown in Figures 12e and 15e, a sealing feature 80 can be used to seal the edges 67c, 68c to the polymeric core 10a at the junction 69 between the two polymer sheets 67, 68. The sealing feature 80 can generally cover and/or fill any gaps and/or irregularities that may exist at the interface and can generally extend a given amount between the polymer sheets 67, 68 and the polymeric core 10a. The polymer sheets 67, 68 can also be pressed into sealing features 80 at the edges 67c, 68c, for example, to help fill any gaps and/or bumps at the barrier 69. Typically, sealing features below the barrier 69 (such as the sealing features 80 shown in Figures 12e and 15e) can be applied after the polymer sheets 67, 68 are bonded to the polymeric core 10a, as the sealing features 80 are located below the polymer sheets 67, 68. The sealing features 80 can also include a sealing liquid, a sealing composition, or a sealing tape, and in another example, can be inserted, injected, pressed, and/or otherwise placed between the polymer sheets 67, 68 and the polymeric core 10a after the polymer sheets 67, 68 are bonded to the polymeric core 10a. In still another example, the sealing features 80 can also be applied to one or both of the polymer sheets 67, 68 prior to bonding, and thereby bonded to the polymeric core 10a simultaneously with the polymer sheets 67, 68. The sealing feature may include any of the sealing features described above, for example, double-sided adhesive tape, a sealing liquid, a chemical sealing composition, a seal produced by a mechanical and/or heat sealing device including an ultrasonic sealing device.

Figures 12f and 15f show an embodiment of a load-bearing structure 10 having a first polymer sheet 67 and a second polymer sheet 68, wherein the first polymer sheet 67 and the second polymer sheet 68 can be connected to each other at an overlap 69'. Overlap 69' can be generally formed by overlapping one of the edges 67c, 68c of the polymer sheets 67, 68, respectively, with the other, as shown by edge 68c located atop edge 67c, and can be produced, for example, by the second polymer sheet being bonded to the polymeric core 10a after the first polymer sheet. In some embodiments, as shown in Figures 12f and 15f, a sealing feature can be used to seal an edge of the polymer sheet to the polymeric core 10a and/or to seal one edge of the polymer sheet to another edge of the polymer sheet, for example, as shown by edge 67c being sealed to the polymeric core 10a and edges 67c, 68c being sealed to each other. The sealing feature 70 can generally cover and/or fill any gaps and/or bumps that may exist at the overlap 69' and can also generally extend a given amount below one of the polymer sheets 67, 68 and/or over the top of polymer sheets 67, 69. Polymer sheets 67, 68 can also be pressed into the sealing feature 70 at edges 67c, 68c, for example to help fill any gaps and/or bumps at the overlap 69'. The sealing feature 80 in Figures 12g and 15g can be applied after one polymer sheet is bonded to the polymer core 10a and before a second polymer sheet is bonded. The sealing feature 80 can also be bonded to one polymer sheet and applied together with it, for example, by applying the sealing feature 80 to the edge of polymer sheet 68 before bonding polymer sheet 68 to the polymer core 10a and polymer sheet 67, where polymer sheet 67 can be bonded before polymer sheet 68. In yet another example, the sealing feature 80 can also be inserted, injected, pressed, and/or otherwise placed between the polymer sheets 67, 68 and the polymeric core 10a after the polymer sheets 67, 68 are bonded to the polymeric core 10a. The sealing feature may or may not be activatable at the temperatures and/or pressures described above for bonding the sheet 67 or 68 to the core 10a.

In another embodiment, as shown in Figure 12f-1 and 15h, sealing feature 70 is present between the overlapping portion 69 ' of plate 67,68.This sealing feature 70 can be any one of the sealing features described above.For double-sided adhesive tape, it can usually be applied before the second plate 68 is bonded to the core and the first plate, and this adhesive can be activated in the bonding process.This adhesive can be applied to the edge of the side of the second adhesive tape that will be bonded to the core.For sealing liquid, it can be applied after the bonding process.

Figures 12g and 15g show an embodiment of a load-bearing structure 10 having a first polymer sheet 67 and a second polymer sheet 68, wherein the first polymer sheet 67 and the second polymer sheet 68 can be connected to each other at an overlap 69'. The overlap 69' can generally be formed by overlapping one of the edges 67c, 68c of the polymer sheets 67, 68 with the other, as shown by edge 68c located on top of edge 67c, and can, for example, be produced by the second polymer sheet being bonded to the polymer core 10a after the first polymer sheet. In some embodiments, as shown in Figures 12g and 15g, a sealing feature 80 can be used to seal the edges of the polymer sheets to each other, as shown by the edges 67c, 68c being sealed to each other. The sealing feature 80 can generally cover and/or fill any gaps and/or unevenness that may exist at the overlap 69', and can generally also extend a given amount above the top of the polymer sheets 67, 68. The sealing feature 70 shown in Figures 12g and 15g can be applied after the polymer sheet is bonded to the polymer core 10a, as the sealing feature 80 is located on top of the overlap 69'. The sealing feature may or may not be activatable at the temperatures and/or pressures described above for bonding the plate 67 or 68 to the core 10a. The sealing liquid can be contained in a bottle or box with a dispensing tip or end. The liquid can be dispensed into the edge where the edge of the polymer sheet contacts the surface of the core, or the edge of one thermoplastic sheet contacts the edge of a second thermoplastic sheet after the load-bearing structure is formed. As previously described, the sealing liquid can be a solvent suitable for the core 10a and/or thermoplastic sheet 67 or 68 and can slightly dissolve the material near the surface of the core 10a or the membrane 67 or 68.

In still other embodiments, as shown in FIG14e , the load-bearing structure 10 includes polymer sheets 67 and 68, with the polymer sheet 68 covering the top of the polymer core 10a. The edge 68c of the polymer sheet 68 can overlap the edge of the plate 67 (not shown here) to form a relatively smooth interface, or it can be flattened to include gaps and/or irregularities, such as those that may result from the manufacturing and/or connection process of bonding the polymer sheet 68 to the polymer core 10a. A sealing feature can then be used to seal and/or cover the edge 68c of the polymer sheet 68 as described above and/or extend over the polymer core 10a. The sealing feature can cover and/or fill any gaps and/or irregularities that may exist at the interface and can also typically extend a given amount over the polymer sheet 67 and/or polymer core 10a, for example, to create a more robust and/or durable seal. Typically, a sealing feature that covers the polymer sheet edge, whether or not overlap 69a is present, and which may be part of polymeric core 10a, may be applied after polymer sheets 67, 68 are bonded to polymeric core 10a, since the sealing feature sits atop polymer sheet 68. The sealing feature may comprise any of the sealing features described above, such as, for example, a single-sided adhesive tape.

Additionally, there may be an indentation in Figure 14e that extends from the bottom edge or polymeric core 10a to a portion of the width near the bottom edge to accommodate the edge protector 11' as shown in 26a. The indentation may not be visible if the edge protector is located between the core and the polymeric sheet or plate.

The sealing liquid can be applied like the sealing features 70, 80 described above, and can be applied before or after the polymer sheet is bonded to the polymer core. The sealing liquid can also be applied to the polymer sheet. If the liquid is applied before the membrane 67 or 68 is bonded to the core 10a or the membranes 67 or 68 are bonded to each other, then the sealing liquid can be activated at the temperature and/or pressure of bonding the plate 67 or 68 to the core 10a as described above. In some embodiments, as described above, the sealing liquid can also be injected under the polymer sheet after completing bonding the plate 67 or 68 to the core and/or bonding the plate 67 or 68 to each other, and thus can be activated without the need for the temperature and/or pressure of bonding the plate 67 or 68 to the core 10a as described above. Figures 13 and 13a show an example of injecting a sealing liquid under a polymer sheet 68, wherein the polymer sheet 68 has been bonded to the polymer core 10a. 13 shows the overlap between the plates 67, 68 (although not visible here) and the sealing liquid being injected under the rim 68c using the syringe 50, thereby bonding the rim 68c to the rim of the plate 67 and/or a portion of the polymeric core 10a. The rim 68c can then be pressed downward, such as by hand or using a press and/or pressing device, such as shown in FIG13a by a human hand 90, for example, to reduce any bumps and/or gaps at the rim 68c and/or to create a more continuous seal.

The sealing compound can be in the form of a processed solid or natural liquid, or even in the form of a suspension. This sealing compound is typically applied to the edge of the polymer sheet before it is bonded to the core, and its sealing properties are typically activated during the bonding process as described above. In one embodiment, the liquid compound may be encapsulated in capsules. The capsules do not adhere to each other, allowing them to flow freely. However, the capsules may adsorb or be attracted to the surface of the film or polymer sheet, allowing them to be applied, for example, by spraying onto the surface to be sealed before the bonding process. The composition can be activated by heat and/or pressure during the bonding process of the core to the panel. In another embodiment, the compound can be applied directly in liquid form, similar to the application of the sealing liquid described above, and may or may not need to be activated at the temperatures and/or pressures used to bond panel 67 or 68 to core 10a. For example, as described above, the liquid compound can also be mixed with polymer particles to form a suspension. In this embodiment, when the polymer sheet is made of high-impact polystyrene, the powder is the polystyrene in powdered form. The sealing liquid may be relatively non-volatile, such that the liquid does not substantially evaporate prior to the bonding process between the panel and the core and/or the panel. The chemical sealing composition may also include a self-healing and/or self-repairing composition. Such compositions are desirable because sealing features may be present in high pressure, high damage, and/or high wear environments, and the use of self-healing/self-repairing materials may increase the efficiency and/or service life of the load-bearing structure.

When using sealing tape, the tape can include a side with a contact or tacky adhesive and another side with a heat-activated adhesive. The tacky or contact adhesive side can be covered by a liner, and the tape can be wound into a roll as shown in Figure 14. Afterwards, the roll 63 of the tape 60 can be unfolded manually or by a tape dispenser and the liner 61 can be removed to expose the tacky or contact adhesive surface 62 shown in Figure 14a and the example of the tape dispenser 30 in Figure 14a-1. The tape 60 shown can be a double-sided adhesive tape or a single-sided adhesive tape and can include a liner that can later serve as a sealing feature such as sealing features 70, 80, and as described above and shown in the tape 60, the edge of the polymer sheet and/or the polymer core to which it is applied, wherein the tape 60 is applied on the polymer sheet 67 and on the polymer core 10a, while the liner 61 is being removed to expose the tacky or contact adhesive surface 62 in Figures 14b and 14c. In some embodiments, the tape 60 may be double-sided, while in other embodiments, the tape 60 may be one-sided, such as the tape 60 in FIG. 14 d , and may be applied over the bonding interface.

On the other hand, the heat-activated adhesive can include a hot melt adhesive, a thermosetting adhesive, or a reactive adhesive. The heat-activated adhesive can be selectively activated at a temperature during the bonding process.

In some embodiments, the sealing features 70, 80 may include a self-recovering and/or self-healing composition as described above. Such a composition is desirable because the sealing features 70, 80 may be present in high pressure, high damage and/or high wear, and it can increase the efficiency and/or service life of the load-bearing structure by using a self-recovering/self-healing material. For example, some polymers can recover and/or repair tears and/or other damage by contact repolymerization and/or contact adhesion of adjacent edges of polymeric materials. These polymers may include, for example, polymers that repolymerize with each other when exposed to ultraviolet light and/or other electromagnetic radiation and/or heat. For example, a polyurethane-deacetylated chitosan hybrid polymer can be repolymerized using ultraviolet light to restore tears and/or other discontinuities. For another example, a new class of polymers can also be used that is formed from a condensation reaction between paraformaldehyde and 4,4'-diaminodiphenyl ether developed by IBM. As described above, any of the various sealing features described herein may include a self-recovering and/or self-healing composition.

In other embodiments, sealing features 70, 80 may comprise melting, welding, sintering, and/or other heat/pressure bonding of materials in polymer sheets (e.g., polymer sheets 67, 68 and/or polymer core 10a). For example, ultrasonic welding may be used to melt and/or bond the edges of the polymer sheets together and/or to bond the edges of the polymer sheets to polymer core 10a using localized heating. The bonded areas may be subjected to pressure.

In some embodiments, as shown in Figures 12h-12m, the polymer sheets can be folded over one another at an interface. The interface can also be subjected to heat, pressure, and/or vacuum to help connect the polymer sheets together at the fold and/or to bond the polymer sheets to the polymer core. In one embodiment, a retaining device, such as retaining device 40 in Figure 12h, can be used to secure at least one polymer sheet and/or polymer core in place to facilitate folding and sealing the polymer sheets. The polymer core 10a can be inserted into a first polymer half 67 resting against retaining device 40. For example, the first polymer sheet 67 can be sufficiently rigid at this stage to remain substantially vertical during the bonding process until it is subjected to additional heat, pressure, and/or mechanical forces to induce folding. For example, while the first polymer sheet 67 is being bonded to the polymer core 10a (not shown), it can be secured vertically in place so that the polymer sheet is properly vertically oriented at its edges upon cooling and regaining its rigidity. In some embodiments, as shown in FIG12h, polymeric core 10a may also include a chamfered corner 12', which may be beveled, for example, at approximately 45 degrees, for example (for another example), to facilitate folding of the polymer sheets. A second polymer sheet 68 may be placed on polymeric core 10a and may also be overlaid on the vertical edge of first polymer sheet 67 to form enclosed region 45, as shown in FIG12i. This second polymer sheet 68 may also be secured to a retaining device 40 at edge 68d, for example, to help secure polymer sheet 68 in place during folding. Once polymer sheets 67, 68 are positioned, they may be folded over one another, as shown in FIG12j. For example, end 67d of polymer sheet 67 may be folded toward beveled edge 12', while fold 68e of polymer sheet 68 may be folded into enclosed region 45. This folding operation may be facilitated by heating polymer sheets 67, 68, applying pressure and/or mechanical force to the region, and/or applying a vacuum, for example, to enclosed region 45. Once the fold is complete, as shown by the sandwiched fold of end 67d and fold 68e in Figure 12K, heat and/or pressure can be used to seal the fold, for example, so that the polymer sheets 67, 68 can be bonded together, for example, by melting, welding, and/or otherwise adhering to each other. An adhesive similar to a heat-activated adhesive can also be present in the area and activated by heating the fold to help create a sealed interface. Thereafter, excess material of the polymer sheet 68 is trimmed away, leaving a cut edge that can be away from the load-bearing area as shown in Figure 12I. As shown in the close-up view in Figure 12m, the completed interface can thus include, for example, a polymer sheet 67 sandwiched between two layers of polymer sheets 68 at the beveled edge 12', and a cut edge 68f away from the interface. These edges can also be combined with sealing features to improve the bonding defects described above.

In some embodiments, the load-bearing structure 10 may also include grooves, valleys, and/or other features to indicate where the polymer sheet can be trimmed and/or cut, as exemplified by groove 12d in FIG. 25. The groove 12d may be present around the entire circumference of the width portion 12, for example, so that a feature is provided to guide trimming of the polymer sheet. This may be desirable, for example, where only one polymer sheet may be bonded to the polymer core, and the edge of the polymer sheet may be trimmed shorter than the load-bearing surface 16 so that the edge does not cover a portion of the load-bearing surface 16, thereby preventing the edge of the polymer sheet from catching cargo when loaded and/or unloaded.

In some embodiments, as described above, edge protectors, including but not limited to those shown in Figures 26 and 26a, may also be used on the load-bearing structure. In one aspect of the present invention, when cargo is loaded on the load-bearing structure, the cargo may be secured in place on its surface by cargo securing devices such as straps, tiedowns, anchors, cables, and/or other items. In a typical embodiment, the load-bearing structure may be reinforced with protectors 11 or 11' continuously or at locations where the cargo securing devices contact or wrap around the load-bearing structure in predetermined areas or at random locations on the load-bearing structure. In some embodiments, the protectors may be edge protectors that may be located approximately around the circumference of the load-bearing structure. This may be desirable, for example, because when cargo securing devices are used, the bottom edge and the width portion near the bottom edge of the load-bearing structure typically bear the greatest forces from the cargo securing devices. In one embodiment, protectors may be intermittently present at predetermined locations on the load-bearing structure 10, as shown in Figure 25 with recesses 12b and edge protectors 11, where reinforcement may be required. For example, the protectors can distribute the forces and/or pressures applied by cargo securements across a larger area of the load-bearing structure and/or reinforce the area where the cargo securements are located. For example, the protectors can also be stiffer than the underlying portion of the load-bearing structure, which, for another example, can better distribute the forces applied to the load-bearing structure without causing significant deflection, deformation, or damage. In other embodiments, the protectors can be present around the entire circumference of the load-bearing structure, rather than being present at intervals. Cargo securements can be used at these same predetermined locations or other locations to help hold cargo in place. Figure 24 shows an embodiment of a load-bearing structure that can generally include a top side 16 and a width portion 12, wherein cargo can be loaded (not shown) at the top side 16, and the width portion 12 can be vertical or substantially perpendicular to the top side 16. In some embodiments, the load-bearing structure 10 can also be used with edge protectors. Figure 24 shows a load-bearing structure 10 that can include a plurality of recesses 12b along the width portion 12, into which edge protectors can be placed. Typically, recesses 12b can be sized to accommodate edge protectors, for example, so that they are flush with the surface of width portion 12. Recesses 12b can be placed at regular and/or predetermined intervals about width portion 12 and can generally be located where cargo securing items can contact load-bearing structure 10. In some embodiments, as shown in FIG. 24a , the bottom side of load-bearing structure 10 can include a channel 13 in which cargo securing items can be placed. As shown, recesses 12b can thus be located at the ends of channel 13. As shown in FIG. 24b and 24c , recesses 12b can generally have end lip 12c. In other embodiments, load-bearing structure 10 can include recesses 12b, and as shown in FIG. 24d and 24e , the bottom side of load-bearing structure 10 may not include channel 13. Lip 12c can be slightly more visible than the remainder of recess 12c and can help position recess 12b and/or edge protectors in the proper location.

FIG. 25 shows an example of a load-bearing structure 10 having edge protectors 11 in place at recesses 12 b as described above.

As described above, the end edges 12c of the depressions 12b can be present on the polymeric core 10a, and the edge protectors can be positioned in the depressions 12b between the end edges 12c such that they are flush or substantially flush with the remainder of the polymeric core 10a. The protectors may or may not be readily visible and/or discernible after being covered with the polymeric film or sheet. If the protectors themselves are not visible or discernible when in place on the polymeric core 10a, an indicator may be present, such as a visible line of the end edges 12c and/or a small indentation discernible by tactile inspection.

In some embodiments, the edge protector can have an L-shaped cross-section, as shown in FIG26 , which shows an L-shaped end protector 11 having an outer surface 11a and an inner surface 11b , wherein the outer surface 11a can, for example, contact a cargo securing item, while the inner surface 11b can contact a recess 12b . The L-shaped edge protectors 11 can be spaced or continuous around the bottom and width of the core, where the L-shaped edge protectors 11 wrap around a portion of the bottom side near the outer edge, wrapping around the edge and extending over a portion of the width near the bottom side, as shown in FIG25 a , a partial schematic diagram of a load-bearing structure 10, in which the L-shaped edge protectors 11 are seated in recess 12b on the core 10a .

In other embodiments, the edge protector may have a substantially C-shaped cross-section, as shown in FIG26a , which shows a C-shaped end protector 11′ having an outer surface 11a and an inner surface 11b , wherein the outer surface 11a may, for example, contact a cargo securing item, while the inner surface 11b may contact the recess 12b . The C-shaped edge protector 11′ may be spaced or continuous around the bottom, width, and top of the core, in a manner such that the C-shaped edge protector 11′ wraps around a portion of the bottom side near the outer edge, wraps around the edge, and extends over the width and a portion of the top side near the width, as shown in FIG25b , a schematic partial cross-sectional view of the load-bearing structure 10, in which the C-shaped edge protector 11′ is wrapped around the width 12 and seated in the recess 12b . According to another embodiment, the edge protectors may be present in pairs, each having a substantially L-shaped cross-section, and may be spaced or continuous around the bottom, width, and top of the core in a manner such that one protector in each pair wraps around a portion of the bottom side near the outer edge, wrapping around a portion of the edge, while the other extends over a portion of the width near the top side and a portion of the top side near the width, which may then appear similar to C-shaped edge protector 11'. Each pair of protectors may or may not be sufficient when placed on the load-bearing structure 10. In other embodiments, the load-bearing structure 10 may include separate recesses for the upper and lower edges of the width portion 12, as shown in the partial cross-sectional schematic diagram of the load-bearing structure 10 in Figure 25c, in which there is an upper recess 12b-1 and a lower recess 12b, and edge protectors 11-1 and 11, wherein the edge protectors 11-1 and 11 are respectively located in the separate portions 12e of the width portion 12, and the separate portions of the width portion 12 are exposed between the edge protectors 11 and 11-1.

In some embodiments, the edge protector, as shown in Figures 27 and 27a, may also include guides and/or other features for securing cargo tie-downs. As shown, the edge protector 11" may include guides 11c that may be used to guide and hold cargo tie-downs in place, such as the straps securing cargo 490 to the load-bearing structure 10, as shown in Figure 27a. This may be desirable, for example, to help prevent lateral movement or slippage of the straps. The guides 11c may also protrude and help the edge protector 11" be visible, thereby allowing cargo tie-downs to be positioned over the edge protector.

In some embodiments, the protector may be present on the core as previously described before the polymer sheet is applied to the core. In one aspect, as described above and shown in Figures 24-26a, the core may be indented to accommodate the protector so that the protector is flush with the core, thereby allowing the plate to cover the core with the protector as if the protector were not there. In another aspect, the core may be indented but not sufficiently to accommodate the entire thickness of the protector so that after covering with the plate, a small amount of protrusion may exist where the protector existed, as exemplified by the edge protector 11" sticking out as a protrusion in Figures 27 and 27a. In another embodiment, the protector may be added after the core is covered with the polymer sheet or plate.

The protector can be made of any polymeric or metallic material, or combination thereof, that can be easily molded or cast into the desired shape and is rigid or substantially rigid or provides sufficient reinforcement for the edge. In one embodiment, when the protector is present on the core before covering the core with a polymer sheet or plate, the protector can be made of the same material or a material having similar bonding properties as the plate so that the protector bonds to both the plate and/or the core at the temperature at which the plate is bonded to the core. This may be further desirable because a load-bearing structure composed essentially of a single material can be more conveniently and/or easily recycled. When an edge protector is present on the core, the polymer sheet or sheets may or may not be bonded or adhered to the edge protector, provided that the edge protector is not made of a similar material or is not bonded or adhered to one or more polymer sheets, and the outer edges of the sheets are bonded to the edge protector using a sealing feature.

In another embodiment, when the protector is added to the load-bearing structure after the panel or panels are bonded to the core, any material may be used for the protector.

In addition to materials that are the same or similar to the polymer sheet, suitable materials for edge protectors, particularly those that reside on the load-bearing structure after the core is bonded to a single panel or panels, may include any metal and polymeric material that can be manufactured into a rigid or substantially rigid part. Examples of suitable materials include, but are not limited to, polymers that can be molded, thermoformed, or cast. Suitable polymers include polyethylene; polypropylene; polybutylene; polystyrene; polyesters; polytetrafluoroethylene (PTFE); acrylic polymers; polyvinyl chloride; acetal condensation polymers such as polyoxymethylene or polyoxymethylene resin (available from DuPont); natural or synthetic rubber; polyamides, or other high temperature polymers such as polyetherimides, which are polymer alloys similar to resins, thermoplastic polycarbonate plastics, where the resin is a composite of polycarbonate and polybutylene terephthalate fibers, and thermoplastic polycarbonate plastics, which are polycarbonate and isophthalate terephthalate resorcinol resins (all available from General Electric Plastics). Plastic); liquid crystal polymers, such as aromatic polyesters or aromatic polyester amides, polyester imine anhydrides, or combinations thereof, wherein the aromatic polyester or aromatic polyester amide comprises at least one compound selected from the group consisting of aromatic hydroxycarboxylic acids (such as hydroxybenzoates (rigid monomers) and hydroxynaphthoates (elastomeric monomers)), aromatic hydroxyamines, and aromatic diamines (as exemplified by U.S. Patents 6,242,063, 6,274,242, 6,643,552, and 6,797,198, the contents of which are incorporated herein by reference), and the polyester imine anhydride has terminal anhydride groups or lateral anhydrides (as exemplified by U.S. Patent 6,730,377, the contents of which are incorporated herein by reference). Some of these materials are recyclable or are manufactured to be recyclable. Fermentable or biodegradable materials can also be used, and can include any biodegradable or biofermentable polyesters, such as polylactic acid resins (including L-lactic acid and D-lactic acid) and polyacetic acid alcohol (PGA), polyhydroxyvaleric acid/hydroxybutyric acid resins (polyhydroxybutyrate (PHBV)) (copolymers of 3-hydroxybutyric acid and 3-hydroxyvaleric acid) and polyhydroxyalkanoate (PHA) copolymers, and polyester/polyurethane. Some non-fermentable or non-biodegradable materials can also be processed to be fermentable or biodegradable by adding a certain amount of additives, for example, any oxo-biodegradable additives, such as D2W ^™ provided by Symphony Environmental, Borehamwood, United Kingdom, and manufactured by EPI Environmental Products Inc. Vancouver, British Columbia, Canada.

Furthermore, any polymer composite material, such as an engineered prepreg or composite material, may be used. These polymers are filled with pigments, carbon particles, silica, glass fibers, or mixtures thereof. For example, a mixture of polycarbonate and ABS (acrylonitrile-butadiene-styrene) may be used. As another example, carbon fiber and/or glass fiber reinforced plastics may also be used.

Applicable metals or metal materials may include metals and metal alloys, such as aluminum, steel, stainless steel, nickel titanium alloy, etc.

To help hold the protector in place on the core before and during the bonding process, an adhesive or double-sided adhesive tape may be used. This may be desirable, for example, because the protector may not be sufficiently adhered and/or clamped to the load-bearing structure before the bonding process. Examples of adhesives include pressure-sensitive adhesives, such as hot melt pressure-sensitive adhesives or non-hot melt pressure-sensitive adhesives. Examples of double-sided adhesive tapes include double-sided adhesive pressure-sensitive adhesive tapes, such as double-sided hot pressure-sensitive tapes or double-sided non-hot melt pressure-sensitive tapes. The thickness of the adhesive or tape can be very thin, such that the adhesive or tape does not substantially increase the thickness of the edge protector and/or does not prevent the edge protector from significantly protruding from the surface of the load-bearing structure. In some embodiments, the adhesive or tape may substantially melt during the bonding process. The amount of adhesive or tape may also be minimal, such that it does not significantly affect the overall material composition of the load-bearing structure, which may be desirable because the load-bearing structure can be more conveniently and/or easily recycled when composed essentially of a single material.

In other embodiments, the protector may utilize friction fits, roughened and/or textured contact surfaces, and/or other mechanical means to attach and/or secure it in place on the load-bearing structure.

To keep the edge protectors securely in place after they emerge from the bonding process, a structural adhesive (such as that used in edge seals described above or below) can be used so that the edge protectors do not separate or move around during or after bundling, thereby keeping the cargo in place.

The protector can be of any thickness as long as it provides the desired reinforcement to the edge. Because some materials are more rigid than others, a thinner protector may be sufficiently rigid. For more flexible materials, a thicker member may be required to provide sufficient rigidity.

The edge protectors can be manufactured by molding or casting. In one embodiment, the edge protectors can be manufactured in batches and then cut to the desired length. In another embodiment, the edge protectors can be individually machined to the desired size. A generally L-shaped edge protector and a generally C-shaped edge protector 11' may also be desirable because the continuous cross-sectional shape allows it to be extruded into a continuous length that can be cut into the desired shape.

The load-bearing structure of the present invention, which may be a pad platform or box, may have antimicrobial properties. An antimicrobial agent is a drug that actively fights one or more organisms, including bacteria, viruses, fungi, protozoa, parasites, and larvae. A foreign host is a bacteria, pathogen, or organism that can be transported on the surface of the load-bearing structure. The antimicrobial agent may be in powder or liquid form.

In an exemplary embodiment, an antimicrobial agent capable of eliminating, preventing, retarding, or minimizing bacterial growth may be placed on exposed surfaces, such as the top side 16 , width portion 12 a , and/or bottom side 18 of the load-bearing structure 10 shown in FIG. 1 .

In any embodiment, when at least one antimicrobial agent is added to the material used to make the polymer sheet of a panel, as described above, or when at least one antimicrobial agent having some surface activity is coated on the exposed surface of the polymer sheet of a panel, as described above, the material comprising the chemical antimicrobial material or compound can exhibit antimicrobial properties, wherein the chemical antimicrobial material or compound is substantially permanently bonded for at least a certain period of time, such as the service life of the load-bearing structure; or when the at least one antimicrobial agent is coated on the polymer sheet of a panel, as described above, with the aid of a coating agent, the antimicrobial agent can maintain its antimicrobial effect. In one embodiment, the chemical can be deposited on the surface of the load-bearing structure via a covalent bond.

When one or more antimicrobial agents are incorporated into the material used to make the polymer layer (e.g., sheet), the one or more agents can be dispersed into the material directly or with the aid of a suitable carrier, such as an adhesive, a solvent, or a suitable polymer mixing aid. These carriers can also be useful for the above-mentioned coating aids. Effective adhesives refer to those adhesives that do not affect the antimicrobial activity of the antimicrobial agent. In one embodiment, when the antimicrobial agent is incorporated into the material used to make the polymer layer (e.g., sheet), the antimicrobial agent can be a masterbatch in the material, or a carrier with a higher concentration before being added to the material used to make the polymer layer (e.g., sheet) in a desired proportion. In another embodiment, the antimicrobial agent can be added directly to the material used to make the polymer layer (e.g., sheet) without an intermediate step.

In other embodiments, the antimicrobial agent in the coating or incorporated into the material used to make the polymer layer may include chemical antimicrobial materials or compounds that can be configured in a non-permanent manner so that they can slowly dissolve, slowly leach, or otherwise release antimicrobial substances during use. When at least one antimicrobial agent is added to the material used to make the above-mentioned polymer layer, or when at least one antimicrobial agent is applied to the exposed surface of the polymer layer (e.g., the above-mentioned sheet), the material can be sufficiently bound, albeit temporarily and/or in sufficient amounts to last for at least a period of time (e.g., the service life of the load-bearing structure); or when at least one antimicrobial agent is applied to the exposed surface of the polymer layer (e.g., the above-mentioned sheet) with the aid of a coating agent, its antimicrobial effect is maintained. Suitable one or more agents are those that tend to slowly migrate to the surface or not leach (as defined herein) to provide the surface with antimicrobial properties.

In other embodiments, the antimicrobial agent in the coating or incorporated into the material used to make the polymeric layer may include a source of the antimicrobial agent that can leach and/or release the agent in a humid environment or upon contact with moisture. These sources may be incorporated into the matrix material used to make the polymeric layer (e.g., the sheet material described above). Incorporation of these sources may be particularly suitable for polymeric matrices.

Chemical antimicrobial materials or compounds may include a variety of substances including, but not limited to, antibiotics, antifungals, general antimicrobials, quaternary ammonium cations, metal ion sources such as metal ion generating materials, triclosan, chlorhexidine or any other material capable of producing an antimicrobial effect, and/or any other suitable compound or mixture thereof.

In another embodiment, antimicrobial activity can be obtained by utilizing the antimicrobial properties of various metals (especially transition metals that have almost no effect on the human body).Examples may include free silver ion sources, which are known for their antimicrobial effect and almost no biological effect on the human body.The antimicrobial activity of metal ions can be produced by a variety of methods, which may include, for example, mixing a metal ion source with a polymer layer (such as a sheet) during manufacture, coating a surface by a method such as plasma deposition, loosely complexing a metal ion source with a polymer layer (such as a coating or a sheet) to form affinity or binding sites by methods such as etching or corona discharge, and configuring metal to the surface by methods such as electroplating, photoreduction, and precipitation.The coated surface can then slowly release the free metal ions that can produce an antimicrobial effect during use.

In some embodiments, the source of metal ions can be an ion exchange resin. Ion exchange resins are materials with ions located in binding sites on their surfaces. Ion exchange resins can be impregnated with specific ionic species, thereby possessing a given affinity. Ion exchange resins can be placed in an environment containing different ionic species, thereby possessing a generally higher affinity, causing the impregnated ions to leach into the environment and be replaced by the ionic species originally present in the environment.

In one embodiment, the polymer layer may include an ion exchange resin containing a metal ion source (e.g., silver). The ion exchange resin containing the metal ion source may include, for example, a product of Milliken Chemical, which is a zirconium phosphate-based ceramic ion exchange resin containing silver. The ion exchange resin may be coated onto the polymer layer, or may be incorporated into a sheet or spray-coated, as discussed above.

In some embodiments, a layer comprising a substantially non-permanent coating of an antimicrobial compound may be present on top of a substantially permanent coating comprising an antimicrobial compound.

The substantially permanent antimicrobial coating can, for example, be substantially flexible so that the coating substantially covers the working surface of the load-bearing structure during use, even when the structure is in a bent state. If the antimicrobial compound itself is not capable of forming a substantially flexible coating, a binder capable of forming a substantially flexible coating can be used to aid in the flexibility of the resulting coating.

A detailed description of antimicrobial coatings and agents can be found in US Patent Application No. 13/549,474, entitled "Load-Bearing Structure Having Antimicrobial Properties," the contents of which are incorporated herein by reference in their entirety.

The load-bearing structure may also include a plurality of bridges, runners, wear-resistant components, and/or connectors that may be attached to the second side of at least some of the extensions or supports 20-28 of all embodiments of the load-bearing structure described herein. The wear-resistant components may typically be attached to the bottom of some of the plurality of supports so that they protrude from the bottom of the supports and contribute to the durability of the supports. Detailed descriptions of wear-resistant components may be found in U.S. Patent Nos. 7,908,979 and 5,868,080, the entire contents of which are incorporated herein by reference.

These wear-resistant components act like bridges or bars extending between adjacent extensions or supports. In some embodiments, there may be only one wear-resistant component. In other embodiments, two of these components may be arranged in a cross configuration. In yet other embodiments, each wear-resistant component may be attached to each pair of adjacent extensions or supports around the periphery of the load-bearing structure. In other embodiments, they may be connected to each pair of extensions or supports of the load-bearing structure.

Strips, bridges and/or other connectors may also be included, such as connecting multiple supports, which generally increase the strength and/or rigidity of the substrate. Figure 21a shows an example of a cross strip 906 connecting multiple extensions or supports 904. Figure 21c shows an example of strips 926 connected in groups of three extensions or supports 924 along two edges. Figure 21d shows an example of strips 916 connecting three groups of extensions or supports 914 in parallel. In general, any desired combination of extensions or supports can be connected by strips or bridges. The strips or bridges can be made of any suitable material. For example, the bridges can be made of wood, metal and/or various plastic materials, including those materials used to make the coating, such as polyolefins, polyesters, lead-free PVC, etc. In some embodiments, the strips or bridges are made of HIPS (high impact polystyrene) by extrusion. In addition, the bridges can be configured so that each of them spans two or more supports in a row and can be attached to the ends of the supports to connect them to each other. For example, the bridge may be adhered using a suitable adhesive.

As described above, the strips or bridges can be attached to the bottom surface of the support member and can be flush with the bottom surface of the support member, for example, attached within a recess formed in the bottom surface of the support member, as shown in Figures 21c and 21d, or protrude from the bottom surface of the support member, as shown in Figure 21a, thereby improving the wear resistance of the support member. In addition, the bottom surface of the strips or bridges can also be roughened to improve the slip resistance of the substrate.

For lightweight load-bearing structures, the core 10a is generally made of a foam material, such as a closed-cell foam core 10a, such as an expanded polystyrene core 10a, which is bonded to a polymer layer in the area adjacent to the surface by heating and/or pressing, and this polymer layer is, for example, a high-impact polymer sheet 67 (such as a polystyrene sheet).

The foam core 10a can be manufactured from pre-produced bulk blocks, such as expanded polystyrene foam, which can be cut into the desired shape and size. The foam density can also vary depending on the degree of expansion of the glass frit used to make the foam. The foam density can also determine the appropriate load capacity or cargo to be loaded.

A typical foam core by itself may not have sufficient structural strength to serve as a load-bearing platform unless it has a higher density, for example, the particles are not highly expanded. A pad platform with sufficient strength can be formed by combining the core 10a with a high-impact polymer sheet 67 (e.g., a polystyrene board). In one embodiment, the sheet 67 may include an antimicrobial agent that can be added to the material used to make the sheet 67. The antimicrobial agent can be in powder form or in liquid form. In another embodiment, at least one antimicrobial agent can be applied to the exposed surface 16 of the sheet 67. The antimicrobial agent can be in powder form or in liquid form. When the antimicrobial agent is applied, it can be applied before the sheet 67 is combined with the core 10a or after the load-bearing structure 10 is formed.

Bonding may be effected by heating and/or pressurizing. In one embodiment of the load-bearing structure, the bonding process may cause portions of the expanded polystyrene core 10a adjacent to the bottom surface 18a to be bonded to the high-impact polystyrene sheet 67 via heating and pressurizing to form a reinforced polystyrene. Additionally, portions of the expanded polystyrene adjacent to the edge 12a and adjacent to the bottom surface 18 may be bonded to the high-impact polystyrene via heating and pressurizing to form a reinforced polystyrene (if desired). A detailed description of this bonding process can be found in US Pat. No. 6,786,992, the contents of which are incorporated herein by reference in their entirety.

Another specific example of the load-bearing structure 10 is disclosed in US Pat. No. 7,908,979, International Application Publication No. WO04041516, and US Pat. No. 7,413,698, all of which are hereby incorporated by reference in their entirety.

In another exemplary embodiment, all of the aforementioned load-bearing structures can be assembled into a box, with these load-bearing structures forming all of the wall, top, and bottom components of the box, as shown in Figures 5-7 and 8, and Figures 8A-8E. The bottom has a plurality of supports extending from below the core 10a, and the side walls and top may or may not include supports. The aforementioned load-bearing structures (e.g., as shown in Figures 1, 12, and 12a-f) include those having an antimicrobial coating capable of eliminating, preventing, delaying, or minimizing bacterial growth. The antimicrobial coating may be present in the material used to make the polymer layer (e.g., sheet) or coated on one or more exposed surfaces.

For example, as shown in FIG4 , the bottom structure of the box can be made of a core 10a combined with a polymer sheet 67, as described above in FIG1 . In FIG3 , a line drawing of a loaded cargo carrying pallet platform with a half shell 380 thereon is shown, wherein the cargo carrying pallet platform is loaded with cargo 490, according to one embodiment of the present invention. Referring again to FIG4 , the cargo carrying pallet platform 10 can serve as the bottom of the box of FIG3 , having a top surface 115 and a rim 110. In this embodiment, the pallet platform 10a shown has six (6) pockets 125 and two (2) grooves or recesses 130 extending through the top surface 115, each of which can extend into the core 10a of the pallet platform 10 (not shown). In one embodiment of the present invention, the pockets 125 can be used to position a phase change material. In one embodiment of the present invention, the grooves or recesses 130 can be used to position one or more shells. FIG4(A) shows the embodiment of FIG3 without the cargo box.

3A shows a cargo loading dunnage platform having a phase change material box or pocket 125a located in pocket 125 and having a half shell located thereon, according to one embodiment of the present invention. These boxes or pockets are shown here as being generally rectangular, but other shapes are possible.

As shown in FIG. 9 , in another embodiment, the bottom portion may be the same as that shown in FIG. 1 , but also has a groove 130 .

In one exemplary embodiment, the box 100 (FIG. 5) or 300 (FIG. 6) can be a removable or collapsible shipping container comprised of multiple surfaces, including a bottom 106 or 306, four walls 101 (103) or 301 (303) and a top panel 404 (as shown in FIG. 7), each of which is made of a lightweight polymer core bonded or laminated to a thermoplastic sheet. In one embodiment of the invention, a structural metal mesh can be inserted into the core 101a (not shown) to resist puncture on any surface. In another embodiment of the invention, the walls can be held together by fasteners 450, as shown in FIG. 7. The shipping and/or storage box 400 is modular, lightweight, and can be thermally insulating and/or tamper-resistant, and provides a sanitary surface coating and thermal capacity for the transportation of food and other valuable products. Upon delivery and unloading, the walls and top of the box can be removed and stacked on a pallet bottom to reduce the volume of the box for storage or subsequent shipment. Details of the tank are described in US Pat. No. 7,963,397, the contents of which are incorporated herein by reference in their entirety.

In another embodiment of the present invention, a removable or foldable box for storage and/or transport includes a bottom, four walls extending from the bottom, and a top panel to form an enclosure, wherein the bottom, walls, and top panel each have an inner surface, an outer surface, a width connecting the inner and outer surfaces, four inner edges, and four outer edges. When the box is folded or disassembled, the area occupied by the box does not exceed the area of the largest single component, as shown in Figures 8, 8A-8E. In one embodiment of the present invention, the bottom, four walls, and top each include surfaces extending substantially along no more than about 80% of the four inner edges of any of the box components, including the walls, bottom, and top, and features on adjacent components have opposing interlocking features, as shown in Figures 8, 8A-8E. That is, if an edge has a groove, the length of the groove is less than 80% of the length of the edge.

In an alternative embodiment of the invention, the bottom, four walls, and top each include a surface extending generally along no more than about 90% of any four interior edges of the walls, bottom, and top of the box components, with features on adjacent components having relative interlocking features. That is, if the edge has a groove, the length of the groove is less than 90% of the length of the edge.

Relative interlocking features can also be defined as depressions on the box wall that correspond to protrusions on the cargo, allowing the box to "fit" with the cargo without the need for fasteners. The interlocking features can include respective recessed and raised features on adjacent connecting components. For example, when the features along one side have a receiving characteristic and the features on the adjacent component have a protruding characteristic, the interlocking features mate to form the box without the need for additional clips or fasteners. The term "no fasteners required" means that the interlocking features do not interlock with any component other than the bottom, four walls, or top. If desired, additional securing devices can be used to ensure further integrity of the box. Such additional securing devices can include tape and/or heat shrink wrap. In one embodiment, each wall, top, and bottom of the box can also be composed of a lightweight core substantially covered by a polymer layer (such as a high-impact sheet), this polymer layer having antimicrobial properties or having at least one antimicrobial agent incorporated therein or thereon, and the load-bearing structure having the above-mentioned width is formed by covering at least one surface of the core with the polymer layer. In another embodiment, a structural metal mesh may be inserted into the core to resist surface penetration, and each wall, top, and bottom of the box may also be constructed of a lightweight core substantially covered by a polymer layer (e.g., a high-impact sheet) that may or may not have antimicrobial properties or incorporate at least one antimicrobial agent therein or thereon, with the polymer layer being applied to at least one surface of the core to form a load-bearing structure having the aforementioned width. FIG8 illustrates a perspective view of an assembled box 800, generally comprising a bottom 812, side panels 801, 802, 803, and 804, and a top 816. Generally, the box 800 can be assembled into the configuration shown in FIG8 without the use of adhesives, fasteners, and/or other assembly aids, and can be assembled and maintained in a generally predetermined pattern. In one embodiment, as shown in FIG8A, the bottom 812 may be generally rectangular and may include a plurality of channels or slots 831, 832, 833, and 834, each located adjacent an edge of the bottom 812. Each groove 831, 832, 833, and 834 terminates at a substantially open corner to the edge, as shown in corners 812a, b, c, and d, so that at least one end of the groove is open to insert the side panel. Corners 812a, b, c, and d may also include a closed edge, thereby acting as a stop, for example, one or more side panels can abut against the closed edge of the corner and remain substantially within the corner and prevent the side panel from exceeding the corner. As shown in Figure 8B, a side panel, such as side panel 801, may include a corresponding ridge 841 that can slide into and be retained in a corresponding groove, such as groove 831 as shown in the figure. A side panel, such as side panel 801 as shown in the figure, may also include a ridge 841a opposite ridge 841, which can correspond to and be retained in the groove of top 816.

Typically, side panels 801, 802, 803, and 804 can include edges that are perpendicular to the ridges of the grooves in top 816 and bottom 812, as shown in the top view of box 800 in FIG8C. Typically, the perpendicular edges can be mated to interlock with each other, as shown by connections 853, 854, and 855. Typically, to assemble box 800, for example, side panel 804 can be inserted into groove 834, then side panel 803 can be inserted into groove 833, side panel 802 can be inserted into groove 832, and then side panel 801 can be inserted into groove 831. Side panels 801 and 802 can include non-interlocking connections, as shown by abutting edges 851 and 852, so that side panel 801 can be inserted without interference from the protruding tabs. As shown in FIG8D , the top 816 can include grooves 833a, 833b, 833c, and 833d that can correspond to the ridges 842a, 842b, 842c, and 842d of the side panels, respectively, and then be positioned so that the corresponding ridges fit into the grooves of the top 816 to close the box 800. The top 816 can also be placed, for example, before all of the side panels are placed, as shown in FIG8E . The side panels (such as side panel 801 in FIG8E ) can also include handle features, such as handle recesses 801d, to make it easier to operate the side panels.

These embodiments of the box are described in detail in US Patent Application Nos. 13/549,472 and 14/158,488, entitled "Cargo Container for Storing and Transporting Cargo," the contents of all of which are incorporated herein by reference in their entirety.

In a further exemplary embodiment, the box includes two identical halves 380 having a generally L-shaped cross-section, each having at least two walls and a bottom or top member, each member having corresponding or complementary interlocking features to fit together to enclose the box, as shown in FIG4A . In other embodiments, the bottom may not have a recess. Each half has an inner surface and an outer surface connected by a width portion. The footprint of the box after disassembly or folding is no larger than that of the halves having a generally L-shaped cross-section. In one embodiment, each half is made of an inner lightweight core covered with at least one layer of reinforcing coating. In another embodiment, a structured metal mesh may be inserted into the core to resist surface puncture. In one aspect, the box may have thermal insulation properties to minimize the exposure of the cargo to low temperatures. In another aspect, the box may have thermal insulation properties to minimize the exposure of the cargo to high temperatures. In yet another aspect, the box may have a combination of the properties described in any of the aforementioned aspects. According to one embodiment, the box may include an outer shell having an undivided inner cavity. According to another embodiment, the box may include an outer shell having more than one internal compartment. These embodiments are also disclosed in U.S. patent application Ser. Nos. 13/549,472 and 14/158,488, both entitled “Cargo Box for Storing and Transporting Cargo,” and 13/254,127, entitled “Temperature-Controlled Cargo Box for Storing, Transporting, and Preserving Cargo,” the contents of which are hereby incorporated by reference in their entireties.

As described above, the boxes include those described in Figures 5, 6 and 7 (which are also disclosed in U.S. Patent No. 8,672,137, the contents of which are incorporated herein by reference in their entirety), at least one of the exposed surfaces of the box also has antimicrobial properties and recesses may be added to accommodate phase change material.

According to one embodiment, the box may include a housing with an undivided interior, as shown in FIG3 , FIG8C , or FIG10 . According to another embodiment, the box may include a housing with more than one interior compartment, not specifically shown. In one aspect, the interior may have dividers molded into the sides of the component structure (not specifically shown). In another aspect, dividers may be added to the box to form separate compartments. As shown in FIG10 , FIG10A , and FIG11A , features 612 or 622 may be present or molded into the components of the box to allow the dividers to be configured to adjust the size of the compartments.

Figures 10, 10A, and 11A illustrate an embodiment of a half of a generally L-shaped cross-section of a box 600 having channels or slots 130 molded or formed into each side. Slots 612 or 622 are molded or formed into the interior of each side panel, bottom, or top member (610 or 620 in Figures 10, 10a, or 11a) for attaching dividers (not shown) to create various compartments within the enclosure, or for attaching formed features 700 for storing cargo, as shown in Figure 11A. In one embodiment, the slots 612 or 622 can be formed or molded at a fixed spacing, as shown in Figures 10, 10A, and 11A, to create compartments of the same size or multiples of a certain size. In another embodiment, the slots 612 or 622 can be formed or molded at different spacings (not specifically shown) to create compartments of different sizes, which may or may not be multiples of a certain size. In one aspect, the slots are formed at corresponding positions on the inner surface of the side, top or bottom member to form compartments substantially parallel to the horizontal or vertical plane. In another aspect, the slots form an angle relative to the horizontal or vertical plane.

According to one embodiment, features 700 may be formed or molded into the box for placing cargo or for placing other components that keep cargo more securely positioned.

FIG. 11 shows a closed box 600 (as shown in FIG. 10 or FIG. 11A ) formed by mating two generally L-shaped cross-sectional halves.

The box may be sized and shaped to accommodate the goods, or the goods may be contained within its own packaging and then inserted into the box 380 or 600.

In some embodiments, a box with an outer shell can also be made from a detachable or foldable box 200 for storage and/or transportation, as shown in FIG16 , which has a bottom, four walls extending from the bottom, and a top panel to enclose the outer shell. The four walls are substantially similar in shape and have the same interlocking features, so that the box 200 can have at least three different parts: a top panel, a bottom panel, and a wall panel. The same interlocking features on the wall panels can also generally help to form a box 200 that is rigid, resilient, and easy to assemble/disassemble.

16 shows a perspective view of a box 200, which may include a top panel 210, four wall panels 220, and a bottom panel 230. The wall panels 220 may generally be connected to each other at side interfaces 204 to form a generally rectangular enclosure having a space 201 as shown in FIG16 a. The wall panels 220 may then be joined to the bottom panel 230 at a bottom interface 206 and to the top panel 210 at a top interface 202.

Typically, as shown in Figures 17 and 17a, the bottom 230 can include a main platform 232 on which cargo and/or other materials can rest when the box 200 is assembled. As described above, when assembled, the main platform portion of all components defines the interior space of the box 200. The bottom 230 can also typically include a plurality of supports, such as extensions or supports 238 that can extend from the bottom surface 231, as shown in Figure 17a. At the bottom interface 206 with the wall panels 220, the bottom 230 can typically include an interface feature, such as a circumferential groove 236 between the main platform 232 and an outer peripheral ring or rim portion 234, as shown in Figure 17. Typically, a portion of the wall panels 220 can be connected to the bottom 230 by being inserted into the circumferential groove 236. A portion of the wall panels 220 can also rest on the top surface 235 of the circumferential ring 234, allowing, for example, the wall panels 220 and the bottom 230 to be connected at the bottom interface 206 with minimal gap or space. The bottom 230 may also have rounded corners, chamfers and/or other smooth edges to minimize pointed and/or protruding portions of the box 200, such as the chamfered edge 237 and rounded corners 239 of the circumferential ring 234 and the rounded corners 233 of the main platform 232, as shown in Figure 17.

As shown in Figures 19 and 19a, the top plate 210 can generally include a main platform portion 212 and an outer surface 211. When the box 200 is assembled, the main platform portion 212 can form a roof. At the top interface 202 with the wall panels 220, the top plate 210 can generally include interface features, such as a circumferential groove 216 between the inner main platform portion 212 and the outer peripheral ring 214, as shown in Figure 19a. Generally, a portion of the wall panels 220 can be connected to the top plate 210 by inserting into the circumferential groove 216. A portion of the wall panels 220 can also rest on the bottom surface 215 of the peripheral ring 214, so that, for example, the wall panels 220 and the top plate 210 can be connected at the bottom surface 202 with minimal gap or space. The top plate 210 may also have rounded, chamfered, and/or otherwise shaped edges to minimize tips and/or protruding portions of the box 200, such as the chamfered edge 217 and rounded corners 219 of the circumferential ring 234 and the rounded corners 213 of the main platform portion 212, as shown in Figures 19 and 19a.

Each wall panel 220 can generally include four rectangular panels 222 having interface features on their edges. In some embodiments, three of the four edges can be formed as stepped edges having a portion of the total thickness of the rectangular panel 222 extending outwardly to form a partial circumferential step, such as stepped edges 226a, 226b, and 226c forming step 226 as shown in Figures 18 and 18e. The fourth edge can be formed as a coiled extension, such as an extension 224 having a portion of the total thickness of the rectangular panel 222 as shown in Figures 18 and 18a, which extends from edge 223 and coils at an angle of approximately 90° relative to the plane of the rectangular panel 222 toward the inner surface 228 of the rectangular panel 222, which can generally form a channel or groove between the coiled portion of the extension 224 and the unextended edge 223a of the rectangular panel 222, such as groove 225 as shown in Figures 18 and 18a.

The stepped edges 226a, 226b, and 226c are typically configured to fit into grooves in other components of the box 200, such as edge 226a fitting into circumferential groove 216 of the top panel 210 shown in FIG18b, edge 226b fitting into groove 225 of another wall panel 220 shown in FIG18c, and edge 226c fitting into circumferential groove 236 of the bottom 230 shown in FIG18d. This generally allows for a substantially continuous interface with minimal spacing and/or gaps between the components at the top interface 202, the side interface 204, and the bottom interface 206. The interface grooves, extensions, and/or corner interface can also generally function as tongue-and-groove interfaces and can thereby provide a rigid and/or largely self-supporting connection between the components, minimizing any reinforcement that may be required when assembled. These interfaces can also generally resist loads in all directions.

In other embodiments, as shown in Figures 18 and 18a, the wall panel 220 may also include an outer panel 222 that is connected to and/or formed as a single component with an inner panel 226. The outer panel 222 may generally include an interface feature on one side, such as at a corner interface 234, which may generally extend beyond the edge of the inner panel 226, as shown. In some embodiments, the corner interface 234 may generally include a generally L-shaped cross-section, allowing it to substantially span a 90° angle to connect with another wall panel 220. The L-shaped cross-section of the corner interface 234 may generally form a slot 225 between the corner interface 234 and the inner panel 226.

The inner panel 226 can generally include an interface that extends beyond the edge of the outer panel 222 (except at the edge with the corner interface 234), such as having extensions 226a, 226b, and 226c, as shown. The extensions 226a, 226b, and 226c can generally be shaped to fit into grooves of other components of the box 200, such as, for example, the extension 226a fits into the circumferential groove 216 of the top panel 210 shown in FIG18b, the extension 226b fits into the groove 225 of another wall panel 220 shown in FIG18c, and the extension 226c fits into the circumferential groove 236 of the bottom 230 shown in FIG18d, which can generally form a substantially continuous interface between the components at the top interface 202, the side interface 204, and the bottom interface 206 with minimal spacing and/or gaps. Abutment grooves, extensions, and/or corner joints can also typically function as tongue and groove interfaces and can therefore provide a rigid and/or largely self-supporting connection between components, requiring minimal if any reinforcement when assembled. These interfaces can also typically resist loads in all directions.

In some embodiments, the wall panels 220 can be identical and can form a box having a square cross-section. It may be desirable to have a total of three different components required (top panel, bottom panel, and wall panels). In other embodiments, wall panels 220 of different sizes can be used, for example, using two wall panels of one length and two wall panels of another length to create a rectangular box cross-section. Generally, the dimensions of the top panel 210 and bottom panel 230 can determine the type of wall panels 220 required to be used.

Generally, the box 200 can be assembled by connecting the wall panels 220 to the bottom 230 and closing with the top panel 210, as shown in Figure 20. Since all of the corner interfaces 224 and the extensions 226a, 226b, and 226c protrude from one plane, the wall panels 220 can be inserted into the bottom 230 one at a time by, for example, an assembler, and the wall panels 220 can be connected to each other and to the bottom 230 by purely vertical translation, as shown in Figure 20, which may be suitable for reducing awkward and/or difficult assembly steps.

The bottom of the box typically includes a plurality of supports, such as extensions or supports, which can take various forms or shapes, such as the extensions or supports of the bottoms 900, 910, 920, and 930 shown in Figures 21, 21a, 21b, 21c, 21d, and 21e. The supports typically separate the bottom surface of the bottom from the ground and/or other surfaces. The supports can also be spaced apart from one another, for example, so that the bottom can be maneuvered into the spaces between the supports using a forklift and/or other moving machinery.

21 and 21a illustrate a plurality of extensions or supports 904 extending from a bottom surface 902 of a base 900. In some embodiments, the extensions or supports may have angled walls and may have outer walls that are substantially perpendicular to the bottom surface 902 at the periphery of the base, as shown by the extensions or supports 904.

In some other embodiments, the extensions or supports may have angled walls and be spaced inward from the outer edge of the base, such as the extensions or supports 914, 924, and 934 of bases 910, 920, and 930 shown in Figures 21b, 21c, 21d, and 21e, respectively.

The bottom surface of the base and/or the sides of the support member may also include ridges, ribs, reinforcements, and/or other surface modifications, as shown in Figures 21b, 21c, and 21d, for example, to help increase the structural strength and/or stiffness of the base, particularly under load. It is also believed that the ability of the support member and/or base to resist compressive loads will be significantly improved if each side wall includes a plurality of generally longitudinally extending ribs. Figures 21b and 21d illustrate examples of interconnected ridges or ribs 913 on the walls and bottom surface 912 of an extension or support member 914. Figure 21c illustrates an example of grooves 923 on bottom surface 922, with unconnected ridges or ribs on extension or support member 924. Figure 21e illustrates an example of larger raised ribs 933 on bottom surface 932, with extension or support member 934 extending from ribs 933. The cargo box may also include a desiccant to control humidity within the compartment.

In another exemplary embodiment of the present invention, the box 200 is constructed from two halves, and each half may or may not include a top or bottom component. The interlocking features on the components may include any one or all of the combinations described above. In one embodiment, the box 200 includes two identical or mirrored, generally L-shaped cross-section halves, such as the half 220' shown in Figures 22 and 22a, each half having at least two wall components 220, each having corresponding interlocking features to fit together to form the box, which has a closed housing when mated with the top 210 and bottom 230, as shown in Figure 22b.

In another embodiment of the present invention, the box 200 includes two identical or mirrored generally L-shaped cross-sectional halves, such as halves 210' and 230' shown in Figures 23 and 23a, each half having at least two wall components 220 and a top component 210 or a bottom component 230 connected to the half, respectively, each component having corresponding interlocking features to fit together to form the box, the box having, for example, a closed outer shell.

The box is comprised of two identical, generally L-shaped cross-sectional halves 220' or walls. Each half 220' can be integrally formed or formed by joining two wall portions 220, as discussed above, to connect with the top 210 and bottom 230 components. The walls can generally have the same or similar shape and size, and while integrally formed or joined together, each wall portion still maintains its own platform portion 228. The halves 220' can also include all features that constitute the wall 220. As mentioned above, if the halves 220' are integrally formed, the features that normally connect the two wall portions 220 may not be present, instead forming a reliable, continuous structure. In these embodiments, each half 220' includes two vertical edges, such as interface surfaces 224 and 226b; and two horizontal edges, such as 226a and 226c, for interconnecting with other components, such as with each other, and for connecting with the top 210 and bottom 230 to form the box 200 having an interior space 201, as shown in FIG22b. The halves 220' can nest together, for example due to their shape and identical conformation, which generally saves space during storage in the disassembled form.

In one embodiment, one generally L-shaped cross-section half can be integrally formed or connected to the top component, such as half 210' shown in FIG23a, formed by connecting wall portion 220 to top portion 210. The other generally L-shaped cross-section half can be integrally formed or connected to the bottom portion or bottom component, such as half 230' shown in FIG23, formed by connecting wall portion 220 to bottom portion 230, so that the two halves 210', 230' can be assembled to form a complete closed box 200, as shown in FIG23b. As with half 220', the wall portions of halves 210', 230' can generally have the same or similar shape and size. While integrally formed or connected together, each wall portion still maintains its respective platform portion 228. Halves 210', 230' can also include all features that constitute wall portion 220. Similarly, if halves 210', 230' are integrally formed, features that normally contact the two wall portions 220 with either top portion 210 or bottom portion 230 may not be present, resulting in a reliable, continuous structure. In these embodiments, each half 210', 230' includes two vertical edges, such as edges 224 and 226b, and two horizontal edges, such as 226a and 226c, for interconnecting with other components, such as connecting with each other, and the bottom 230 may include a groove 236 to contact the edge of the half 230', and the top 210 may include a groove 216 to contact the edge of the half 230' to form a box 200 with an interior space 201, as shown in Figure 23b. The halves 210', 230' can be nested together, for example, due to their shape and proximity, which generally saves space during storage in the disassembled form.

For the above-mentioned half parts 210', 220', 230', the edges can be rounded or chamfered, such as the rounded edge 223 shown in the figure, or can be non-circular or smooth substantially 90-degree interface (not shown).

As described above, interface features can be formed at any step in the manufacturing process. In one example, features can be molded in when the components are made. The bottom, top or wall may include a lightweight core, such as a closed-cell foam core, combined with a polymer film or surrounded by a polymer film to form a reinforcement structure. The core may include interface features, and the polymer film that combines or surrounds the step or process may conform to the features of the core. In another embodiment, the features can be forged into the component after the component is made, for example, the bottom, top or wall may include a lightweight core (such as a closed-cell foam core) that is combined with a polymer film or surrounded by a polymer film to form a reinforcement structure. The core does not include any interface features. The interface features can be forged after the core and film are combined, and the exposed surface of the core can remain exposed or a spray coating can be added to cover the exposed surface of the core.

In various embodiments of the one or more pad platforms of the present invention, the first shell and the second shell are made of a core made of one or more materials including expanded polystyrene, polyurethane, polyphenylene oxide, pentane-impregnated polystyrene, a mixture of polyphenylene oxide and pentane-impregnated polystyrene, polyethylene, polypropylene, etc. In various embodiments of the one or more pad platforms of the present invention, the first shell and the second shell are made of a core comprising one or more of the above materials. In various embodiments of the one or more pad platforms of the present invention, the first shell and the second shell are made of one or more thermoplastic sheets or layers including high-impact polystyrene; polyolefins such as polypropylene, low-density polyethylene, high-density polyethylene, polyethylene and polypropylene; polycarbonate; acrylonitrile-butadiene-styrene; polyacrylonitrile; polyphenylene oxide; polyphenylene oxide alloys with high-impact polystyrene; polyesters such as PET (polyethylene terephthalate), APET and PETG; lead-free polyvinyl chloride; copolyester/polycarbonate; or composite HIPS structures as described above.

In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell thermoplastic sheets are formed from a mixture of any of the above-mentioned polymers. In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell are formed from a core having an embedded reinforcement material, the reinforcement material being selected from the group consisting of wire mesh, punched sheet, and the barrier is embedded in the core. In various embodiments of one or more pad platforms of the present invention, the first shell and the second shell are formed from a core having an embedded reinforcement material, the reinforcement material being selected from the group consisting of metal, carbon fiber, aramid, basalt-web blanket and bakelite. As described above, non-metallic boxes can be used when used to facilitate security inspection of air cargo that is transparent to magnetic scanners.

As described above, the polymer layer (e.g., a sheet or coating on the polymer layer) can include a chemical antimicrobial substance or compound that is capable of essentially permanently adhering to the exposed surface of the polymer layer (e.g., sheet or coating 67), at least for a period of time, such as the life of the load-bearing structure or when coated with a processing aid or coating agent. In one embodiment, the chemical can be placed on the surface of the polymer layer (e.g., sheet or coating 67) or incorporated into the material of the polymer layer (e.g., sheet or coating 67). Surface 16 can have inherent antimicrobial activity, for example, by covalently bonding the antimicrobial agent to the surface of the polymer layer (e.g., sheet or coating 67), or if incorporated into the bulk material used to make the polymer layer (e.g., sheet or spray coating), it may migrate to the surface. These covalently bonded materials can minimize microbial growth on the surface, whether it is disposable or reusable. In addition, any microbial organisms that may have the opportunity to attach to the material can be killed by interaction with the coating. For example, quaternary ammonium cations (e.g., N-alkyl-pyridinium) can be used as antimicrobial moieties in covalently attached polymer surface coatings. In one embodiment, the aforementioned poly(4-vinyl-N-hexylpyridinium) (N-alkyl-PVP) is previously known to have an optimal alkyl side chain length for antimicrobial activity. Polyethyleneimine (PEI) has also previously been used as an antimicrobial coating when N-alkylated on its primary amino groups and subsequently N-methylated on its secondary and tertiary amino groups to increase the total number of quaternary ammonium cationic groups. Any such covalently bonded quaternary ammonium cationic polymer coating can be used to provide antimicrobial properties to one or more surfaces of a load-bearing structure. Other examples of quaternary ammonium compounds include, but are not limited to, benzalkonium chloride, benzethonium chloride, methylbenzylethonium chloride, cetaxelium chloride, cetylpyridinium chloride, cetrimonium, cetrimonium bromide, dofanium chloride, ammonium, tetraethylammonium bromide, didecyldimethylammonium chloride, and domiphene bromide.

For incorporating one or more antimicrobial agents into the materials used to make the polymer layer (e.g., sheet or spray coating), the one or more formulations can be dispersed directly into the material or dispersed into the material with the aid of a suitable carrier (e.g., adhesive, solvent, or suitable polymer mixing aid). These carriers can be selected so that they can be mixed with the materials used to make the polymer layer (e.g., sheet or spray coating) and are compatible with the one or more antimicrobial agents used. Effective adhesives are those that do not interfere with the antimicrobial activity of the antimicrobial agent.

As noted above, additional enclosures, such as bag-like enclosures, may be used to cover any of the aforementioned load-bearing structures. The present invention also discloses a system intended to facilitate security inspection procedures, comprising a lightweight load-bearing structure for loading perishable or non-perishable cargo, the load-bearing structure having a top deck, a bottom deck, and a width portion connecting the top and bottom, the bottom deck having a plurality of extensions or supports extending therefrom and cargo loaded onto the top deck of the load-bearing structure; and a bag-like enclosure for covering the cargo and at least a portion of the width portion of the load-bearing structure, the bag-like enclosure having an opening around its periphery that is elastic and adapted to stretch to approximately the width portion of the load-bearing structure. Both the load-bearing structure and the bag-like enclosure of such a structure are transparent to magnetic imaging scanners used in security scans to facilitate security inspections of perishable or non-perishable cargo, large or small, without requiring unloading and reloading of cargo from the load-bearing structure.

The bag-like shell can be made of a film, a fabric sheet or a non-fabric sheet, which has enough strength to stretch and cover the goods and is light enough not to add unnecessary weight to the goods. It can be closed on three sides and open at one end, with some elasticity around the opening of the open end. The goods can be packaged and the bag-like material is stretched over the entire goods, the open end is stretched under the edge of the bottom and labeled at the starting point, and the entire structure can be wrapped with shrink film. The surface of the bag-like material can also have antibacterial properties. Any of the above-mentioned antibacterial embodiments may be suitable. More details are found in U.S. patent application No. 13/549,477, entitled "System for Promoting Safety Inspection of Shipped Goods", the contents of which are hereby incorporated by reference in their entirety.

While the invention has been particularly shown and described with reference to exemplary embodiments, it will be understood by those skilled in the art that changes in form and details may be made without departing from the spirit and scope of the invention.

Claims (101)

1. A load-bearing structure, comprising: A foamed polymer core having a top side, a bottom side, and a width portion, the width portion having a thickness connecting the top side and the bottom side; At least one polymer sheet having a first side with an outer edge, the first side of the polymer sheet including the outer edge being bonded to at least a portion of the bottom side, the width portion and the top side of the foam core; The interface formed between the outer edge of the first side of the polymer sheet and the foamed polymer core includes at least one sealing feature to seal the outer edge of the first side of the polymer sheet to a portion of the polymer core. The sealing feature is located at the periphery of the outer edge of the polymer sheet and is intended solely to minimize adhesion defects at the interface. 2. The load-bearing structure according to claim 1, wherein the at least one sealing feature comprises a sealing fluid, a sealing chemical compound, a self-healing compound, a sealing strip, a mechanical seal and/or a heat seal or a combination thereof. 3. The load-bearing structure according to claim 2, wherein the sealing strip comprises two surfaces, one surface having a heat-activated adhesive and the second surface having an adhesive. 4. The load-bearing structure according to claim 3, wherein the adhesive is directly applied to the heat-activated adhesive. 5. The load-bearing structure according to claim 1, wherein the at least one sealing feature comprises a moderate to good solvent for the core and/or the polymer sheet. 6. The load-bearing structure according to claim 5, wherein the at least one sealing liquid comprises tetrachloroethylene. 7. The load-bearing structure according to claim 1, further comprising at least two load-enclosing structures on top of the load-bearing structure to form a closed box. 8. The load-bearing structure according to claim 7, wherein the at least two load-enclosing structures comprise two identical basic L-shaped cross-sectional halves or two identical clamshell-shaped halves. 9. The support structure according to claim 7, further comprising a plurality of recesses for placing phase change material on one side of the support structure. 10. The load-bearing structure of claim 1, further comprising at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure, for accommodating at least one cargo-holding feature. 11. A load-bearing structure having a top side, a bottom side, and a width portion located between the top side and the bottom side, comprising: A foamed polymer core having a top side, a bottom side, and a width portion, the width portion having a thickness connecting the top side and the bottom side; A first polymer sheet having a first side and a second side with an outer edge, the first side and its outer edge being bonded to at least a portion of the thickness of the bottom side and the width portion of the foam polymer core; and A second polymer sheet having a first side and a second side with an outer edge, the second side and its outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side and the width portion of the foam polymer core, forming an overlap between the outer edges of the first polymer sheet and the outer edges of the second polymer sheet, around the width portion, the overlap having an outer edge; The interface formed between the overlapping outer edges of the first polymer sheet and the second polymer sheet is sealed by at least one sealing feature located at the periphery of the outer edge of the overlapping region, for minimizing adhesive defects at the interface of the overlapping outer edges between the first polymer sheet and the second polymer sheet. 12. The load-bearing structure according to claim 11, further comprising at least two load-enclosing structures on top of the load-bearing structure to form a closed box. 13. The load-bearing structure of claim 11, further comprising at least one edge protector located around the bottom edge and a portion of the width portion adjacent to the bottom edge of the load-bearing structure, for accommodating at least one cargo-holding feature. 14. The support structure according to claim 12, wherein one side of the support structure further includes a plurality of recesses for placing phase change material. 15. The load-bearing structure according to claim 11, wherein the structure further comprises an antibacterial agent. 16. The support structure according to claim 11, wherein the support structure is adapted to accommodate goods produced in a cleanroom for easy shipping and to minimize the risk of contamination or damage. 17. The load-bearing structure according to claim 16, wherein the cargo comprises electronic components or pharmaceuticals. 18. The load-bearing structure of claim 10, wherein the at least one edge protector is received in a recess and located in a region away from any corner. 19. The load-bearing structure according to claim 18, wherein the edge protectors are provided continuously or at intervals around the load-bearing structure. 20. The load-bearing structure according to claim 18, wherein the edge protector has an L-shaped cross-section. 21. The load-bearing structure of claim 18 further includes another edge protector disposed around the top edge and a portion of the width portion adjacent to the top edge. 22. The load-bearing structure of claim 21, wherein the edge protector extends to cover the entire width portion and the top edge. 23. The load-bearing structure according to claim 22, wherein the edge protector has a C-shaped cross-section. 24. The load-bearing structure of claim 18, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 25. The load-bearing structure according to claim 18, wherein the edge protector is flush with the rest of the load-bearing structure. 26. The load-bearing structure according to claim 18, wherein the edge protector extends from the remainder of the load-bearing structure. 27. The load-bearing structure according to claim 18, wherein the edge protector is placed on the core before the core is covered with at least one polymer sheet. 28. The load-bearing structure according to claim 18, wherein the edge protector is placed on the core after the core is covered with at least one polymer sheet. 29. The load-bearing structure of claim 18, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 30. The load-bearing structure of claim 18 further comprises a second polymer sheet with an outer edge, the second polymer sheet being bonded to the foam polymer core on at least a portion of the thickness portion of the top side and the width portion of the foam polymer core, and overlapping between the outer edge of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 31. The load-bearing structure according to claim 29, wherein the outer edge of the first side of the polymer sheet is sealed to a portion of the polymer core by at least one sealing feature. 32. The load-bearing structure of claim 30, wherein at least a portion of the overlapping outer edge between the at least one polymer sheet having a first side with an outer edge and the second polymer sheet is sealed by at least one sealing feature. 33. The load-bearing structure according to claim 2, wherein the at least one sealing feature comprises a moderate to good solvent for the core and/or the polymer sheet. 34. The load-bearing structure according to claim 3, wherein the at least one sealing feature comprises a moderate to good solvent for the core and/or the polymer sheet. 35. The load-bearing structure according to claim 4, wherein the at least one sealing feature comprises a moderate to good solvent for the core and/or the polymer sheet. 36. The load-bearing structure according to claim 33, wherein the at least one sealing fluid comprises tetrachloroethylene. 37. The load-bearing structure according to claim 34, wherein the at least one sealing liquid comprises tetrachloroethylene. 38. The load-bearing structure according to claim 35, wherein the at least one sealing liquid comprises tetrachloroethylene. 39. The load-bearing structure of claim 2, further comprising at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure, for accommodating at least one cargo-holding feature. 40. The load-bearing structure of claim 3 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 41. The load-bearing structure of claim 4, further comprising at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure, for accommodating at least one cargo-holding feature. 42. The load-bearing structure of claim 5 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 43. The load-bearing structure of claim 6 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 44. The load-bearing structure of claim 7 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 45. The load-bearing structure of claim 8 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 46. The load-bearing structure of claim 9 further includes at least one edge protector located around a portion of the bottom side and a portion of the width portion adjacent to the bottom side of the load-bearing structure for accommodating at least one cargo-holding feature. 47. The load-bearing structure of claim 12, further comprising at least one edge protector located around the bottom edge and a portion of the width portion adjacent to the bottom edge of the load-bearing structure, for accommodating at least one cargo-holding feature. 48. The load-bearing structure according to claim 12, wherein the structure further comprises an antibacterial agent. 49. The load-bearing structure according to claim 13, wherein the structure further comprises an antibacterial agent. 50. The load-bearing structure according to claim 14, wherein the structure further comprises an antibacterial agent. 51. The support structure according to claim 13, wherein the support structure is adapted to accommodate goods produced in a cleanroom for easy shipping and to minimize the risk of contamination or damage. 52. The support structure according to claim 15, wherein the support structure is adapted to accommodate goods produced in a cleanroom for shipping purposes and to minimize the risk of contamination or damage. 53. The support structure according to claim 2, wherein the self-healing composite comprises a polyurethane-deacetylated chitosan hybrid polymer, a polymer or combination thereof generated from the condensation reaction of paraformaldehyde and 4,4'-diaminodiphenyl ether. 54. The support structure according to claim 2, wherein the self-healing composite comprises polymers that repolymerize with each other upon exposure to ultraviolet light and/or other electromagnetic radiation and/or heat. 55. The load-bearing structure according to claim 19, wherein the edge protector has an L-shaped cross-section. 56. The load-bearing structure of claim 19 further includes another edge protector disposed around the top edge and a portion of the width portion adjacent to the top edge. 57. The load-bearing structure of claim 20 further includes another edge protector disposed around the top edge and a portion of the width portion adjacent to the top edge. 58. The load-bearing structure according to claim 19, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 59. The load-bearing structure of claim 20, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 60. The load-bearing structure of claim 21, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 61. The load-bearing structure according to claim 22, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 62. The load-bearing structure according to claim 23, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 63. The load-bearing structure according to claim 19, wherein the edge protector is flush with the rest of the load-bearing structure. 64. The load-bearing structure according to claim 20, wherein the edge protector is flush with the rest of the load-bearing structure. 65. The load-bearing structure according to claim 21, wherein the edge protector is flush with the rest of the load-bearing structure. 66. The load-bearing structure according to claim 22, wherein the edge protector is flush with the rest of the load-bearing structure. 67. The load-bearing structure according to claim 23, wherein the edge protector is flush with the rest of the load-bearing structure. 68. The load-bearing structure according to claim 24, wherein the edge protector is flush with the rest of the load-bearing structure. 69. The load-bearing structure according to claim 19, wherein the edge protector extends from the remainder of the load-bearing structure. 70. The load-bearing structure according to claim 20, wherein the edge protector extends from the remainder of the load-bearing structure. 71. The load-bearing structure according to claim 21, wherein the edge protector extends from the remainder of the load-bearing structure. 72. The load-bearing structure according to claim 22, wherein the edge protector extends from the remainder of the load-bearing structure. 73. The load-bearing structure according to claim 23, wherein the edge protector extends from the remainder of the load-bearing structure. 74. The load-bearing structure according to claim 24, wherein the edge protector extends from the remainder of the load-bearing structure. 75. The load-bearing structure according to claim 21, wherein the edge protector is placed on the core before the core is covered with at least one polymer sheet. 76. The load-bearing structure according to claim 21, wherein the edge protector is placed on the core after the core is covered with at least one polymer sheet. 77. The load-bearing structure of claim 19, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 78. The load-bearing structure of claim 20, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 79. The load-bearing structure of claim 21, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 80. The load-bearing structure of claim 22, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 81. The load-bearing structure according to claim 23, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 82. The load-bearing structure according to claim 24, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 83. The load-bearing structure according to claim 25, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 84. The load-bearing structure of claim 26, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 85. The load-bearing structure of claim 27, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 86. The load-bearing structure according to claim 28, wherein the at least one polymer sheet is bonded to the foam polymer core on at least a portion of the bottom side, the width portion, and the top side of the foam polymer core. 87. The load-bearing structure of claim 19 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 88. The load-bearing structure of claim 20 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 89. The load-bearing structure of claim 21 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 90. The load-bearing structure of claim 22 further comprises a second polymer sheet with an outer edge, the second polymer sheet being bonded to the foam polymer core on at least a portion of the thickness portion of the top side and the width portion of the foam polymer core, and overlapping between the outer edge of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 91. The load-bearing structure of claim 23 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 92. The load-bearing structure of claim 24 further comprises a second polymer sheet with an outer edge, the second polymer sheet being bonded to at least a portion of the thickness of the foam polymer core on the top side and the width portion of the foam polymer core, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 93. The load-bearing structure of claim 25 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 94. The load-bearing structure of claim 26 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 95. The load-bearing structure of claim 27 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 96. The load-bearing structure of claim 28 further comprises a second polymer sheet with an outer edge, the outer edge being bonded to at least a portion of the thickness of the foam polymer core on the top side of the foam polymer core and the width portion, and overlapping between the outer edges of the at least one polymer sheet having a first side with an outer edge and the outer edge of the second polymer sheet around the width portion. 97. The load-bearing structure according to claim 79, wherein the outer edge of the first side of the polymer sheet is sealed to portions of the polymer core by at least one sealing feature. 98. The load-bearing structure of claim 89, wherein at least a portion of the overlapping outer edge between the at least one polymer sheet having a first side with an outer edge and the second polymer sheet is sealed by at least one sealing feature. 99. The load-bearing structure according to claim 11, wherein the at least one sealing feature comprises a sealing fluid, a sealing chemical compound, a self-healing compound, a sealing tape, a mechanical seal and/or a heat seal or a combination thereof. 100. The support structure according to claim 99, wherein the self-healing composition comprises a polyurethane-deacetylated chitosan hybrid polymer, a polymer or combination thereof generated from the condensation reaction of paraformaldehyde and 4,4'-diaminodiphenyl ether. 101. The support structure according to claim 99, wherein the self-healing composite comprises polymers that repolymerize with each other upon exposure to ultraviolet light and/or other electromagnetic radiation and/or heat.