FIELD OF THE INVENTION
This invention relates to a flexible raffia grade polyolefin fabric sheet pallet for
handling a load.
BACKGROUND OF THE INVENTION
Wooden pallets are conventionally used as portable supports for storage of heavy loads and for handling heavy loads, especially while loading and unloading the loads with a forklift. A wooden pallet comprises a plurality of wooden sections held together with wooden battens disposed over the sections and nailed or bolted to them. Wooden pallets with loads are generally held by a forklift by engaging the forks of the forklift underneath the pallets. Wooden pallets are prone to fungal/insect attack and the bolts and nails are prone to rusting thereby reducing the life of the pallets. Treated wood is used to overcome the problem of fungal/insect attack. Treated wood is expensive increasing the cost of the wooden pallet. Wooden pallets are non-recycleable and are generally non-reusable and create disposal problems. As wooden pallets require trees, they deplete the natural resources and are not environmental friendly. A wooden pallet is heavy and adds to the weight of the load being handled. It also increases the effective height of the load being handled. Wooden pallets are inflexible and can be a disadvantage in handling certain kinds of loads like bags or flexible containers as they do not contour to the shape of such loads and hold them property. This may cause the load to slip off the pallet and get damaged and result in accidents.
Plastics pallets similar in construction as the wooden pallets but without nails or bolts are also used for storage of heavy loads and for handling heavy loads. Plastics pallets
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made by moulding or made from plastic lumber are expensive. Plastic pallets made of non-biogradable plastics create disposal and environmental problems. Plastic pallets are also inflexible like wooden pallets. Supports for loads comprising plastic sheet and corrugated board (known as slipsheets) have also been in use, but these have limitations in handling heavy loads. While loading and unloading heavy loads with slipsheets, wooden/plastic pallets will need to be used in combination. This will require additional clamps on the forklift; to clamp the slipsheets.
Paper pallets are also used for storage and handling of heavy loads. A paper pallet comprises a pair of paper sheets held together with paper tubes halved along the length inserted between the sheets for engaging the forks of a forklift. Paper pallets are susceptible to moisture thereby reducing the life of the pallets and application areas of the pallets. Paper pallets also have low load bearing capabilities. Non-flexible pallets comprising a base sheet consisting of 80% high density polyethylene (HDPE) mixed with 20% low density polyethylene (LDPE) and formed with two fork engaging passages of the same material heat bonded or welded onto the sheet are also used for storage and handling of loads. Non-flexible nature of the pallets make them unsuitable for handling certain kinds of loads as stated earlier. Also they consume energy in the making thereof.
BE 1015851 describes a solid or perforated auxiliary curved plate for use in place of pallets for handling flexible containers. The auxiliary plate comprises channels for locating forks of a forklift. The auxiliary plate is preferably integrated into the container base. The auxiliary plate is inflexible and is for handling bulk flexible containers. EP 1149777 describes a flexible intermediate bulk container with fork
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engaging guides. The container is provided with two parallel sleeves to accommodate the forks of a forklift. The sleeves form part of the container. EP 83505 relates to a collapsible receptacle with prefabricated lift loops forming part of the receptacle and method of manufacturing the same. US 6105057A describes a flexible container with flowable material. The container comprises single or double layers of polypropylene fabric stitched together to form pockets therein and ply boards inserted in the pocket. US 6155527 describes a base pad of composite construction for supporting an appliance during assembly and shipping. The base pad has a pair of end pieces each having portions for supporting the weight of an appliance, a pair of crosspieces connected to the end pieces to form a substantially rectangular base and a wrapping substantially covering the end pieces and crosspieces. The end pieces are formed of low density material such as expanded polystyrene and the wrapping is formed of medium to high density material such as kraft paper. The base pad comprises a large number of components and is expensive. It is not mechanically very strong because of the composite construction. It is susceptible to moisture because of the kraft paper wrapping thereby reducing the life of the pad and also limiting the areas of use of the pad.
Raffia grade or fabric intermediate bulk container grade (FIBC) polyolefin fabrics are generally used for making bulk containers like bags of various sizes.
OBJECTS OF THE INVENTION
An object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet contours to the shape of the load so to seat and hold the load properly and safely.
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Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet is economical, recycleable and does not create disposal and environmental problems and which is environmental friendly.
Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet is mechanically strong and weather and UV resistant and fungal/insect resistant.
Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet is easy to fabricate and does not consume any energy during the fabrication thereof.
Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet is flat and compact and light weight and is foldable and easy and convenient to transport and which requires reduced space for storage and transportation.
Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet does not significantly increase the height or weight of the load being handled.
Another object of the invention is to provide a flexible raffia grade polyolefin fabric sheet pallet for handling a load, which pallet is user friendly and has versatility to
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handle different kinds of loads and which can be handled manually or by lifting mechanisms like forklifts.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention there is provided a flexible raffia grade polyolefin fabric sheet pallet for handling a load, the pallet comprising a base support having a mass of 180 to 240 grams per square meter and comprising atleast one raffia grade UV inhibited woven polyolefin fabric sheet having the sides thereof hemmed, the pallet further comprising atleast two horizontally disposed double walled tunnels formed on the base support, each of the tunnels being formed with raffia grade UV inhibited woven polyotefm fabric strips folded into double waited hollow members and fixed on the base support and having one or more cellulose paper tubes or cellulose paper tubes halved along the length thereof inserted in the space between the double walls of each of the hollow members in close contact with one another or in spaced apart relationship with one another and optionally fixed to the walls of the hollow members.
According to the invention there is also provided a flexible raffia grade polyolefin fabric sheet pallet for handling a load, the pallet comprising a base support having a mass of 180 to 240 grams per square meter and comprising atleast one raffia grade UV inhibited woven polyolefin fabric sheet having the sides thereof hemmed, the pallet further comprising atleast two vertically disposed double walled tunnels formed underneath the base support, each of the tunnels being formed with raffia grade UV inhibited woven polyolefin fabric strips folded into double walled hollow members and fixed to the bottom surface of the base support at one ends thereof and
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having a cellulose paper tube inserted in the space between the double walls of each of the hollow members and optionally fixed to the walls of the hollow members.
The flexible pallet is preferably made of made of raffia grade UV inhibited polypropylene having MFl of 2.0 to 5.0 G/10 min and xylene solubility of 2.8 to 3.4% or raffia grade polyolefin having grade MFl of 0.8 to 13 G/10 min and density of 0.951 to 0.555 G/CC
The following is a detailed description of the invention with reference to the accompanying drawings, in which
Fig 1 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to an embodiment of the invention;
Fig 2 is a crosssectional view of the pallet of Fig 1 along line A-A in Fig 1;
Fig 3 is an enlarged view of a portion of a tunnel of the pallet of Fig 1;
Fig 4 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to another embodiment of the invention;
Fig 5 is a crosssectional view of the pallet of Fig 4 along line B-B in Fig 4;
Figs 6, 7 and 8 are top isometric views of the raffia grade polyolefin fabric sheet pallets according to different other embodiments of the invention;
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Fig 9 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to another embodiment of the invention;
Fig 10 is a crosssectional of the pallet of Fig 9 along line C-C in Fig 9;
Fig 11 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to another embodiment of the invention;
Fig 12 is a crosssectional view of the pallet of Fig 11 along line D-D in Fig 11;
Fig 13 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to another embodiment of the invention;
Figs 14 and 15 are crosssectional views of the pallet of Fig 13 along lines EE and FF in Fig 13 respectively;
Fig 16 is a top isometric view of the raffia grade polyolefin fabric sheet pallet according to another embodiment of the invention; and
Figs 17 and 18 are views in the directions X and Y of the pallet of Fig 16, respectively.
The raffia grade polyolefin fabric sheet pallet la as illustrated in Figs 1 to 3 of the accompanying drawings comprises a base support 2 made of a flexible raffia grade
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UV inhibited polyolefin woven fabric sheet having the sides thereof hemmed (hemming marked 3) ie folded over and stitched. The sheet comprises two horizontally disposed double walled tunnels 4 fixed on the surface of the sheet. The double walls of the tunnels are marked 4a and 4b. The tunnels are formed by folding raffia grade polyolefin strips into double walled hollow members and stitching (stitching marked 5) the hollow members onto the fabric sheet along the opposite sides 5a, 5b of the hollow members. Instead of stitching the sides of the hollow members, they can be fixed by alternative modes of fixing like bonding with an adhesive, riveting or heat sealing or welding. A pair of cellulose paper tubes 6 halved along the length thereof are inserted in the space between the double walls of each of the tunnels one at each thereof in spaced apart relationship with each other. The paper tubes are optionally fixed to the tunnels by stitching marked 7 or by one of the other modes of fixing as described above. The paper tubes are, preferably used yarn spools cut into halves along the length thereof. The pallet lb as illustrated in Figs 4 and 5 of the accompanying drawings is similar to the pallet of Figs 1 to 3 but comprises a base support 2b made of two flexible raffia grade UV inhibited polyolefin fabric sheets 8a, 8b fixed together by one of the above modes of fixing. The pallet lc as illustrated in Fig 6 of the accompanying drawings is similar to the pallet of Figs 1 to 3 but comprises three paper tubes 6 inserted in each of the tunnels 4 on the base support 2c in spaced apart relationship with one another. The pallet Id as illustrated in Fig 7 of the accompanying drawings is similar to the pallet of Figs 1 to 3 but comprises six paper tubes 6 inserted in each of the tunnels 4 on the base support 2d in close contact with one another. The pallet le as illustrated in Fig 8 of the accompanying drawings is similar to the pallet of Figs 1 to 3 but comprises seven paper tubes 6 inserted in each of the tunnels 4 on the base support 2d in close contact
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with one another. The base support 2 also comprises eyelets 9 formed therein. The tunnels of the pallets as illustrated above act as engaging grooves for the forks (not shown) of a forklift (not shown) or similar lifting mechanisms for handling ie lifting or lowering loads (not shown) located on the pallets. The tunnels also can act as strapping or slinging grooves for handling the loads. The eyelets of Fig 8 also can act as strapping or slinging holes for handling the loads.
The pallet If as illustrated in Figs 9 and 10 of the accompanying drawings is similar to the pallet of Figs 1 to 3 but comprises five tunnels 4 formed on the base support adjacent to one another. Each of the tunnels comprises six paper tubes 6 inserted therein in close contact with one another. Besides providing access for the forks of a forklift or for strapping, the tunnels also provide certain amount of rigidity and strength to the pallet. The pallet lg as illustrated in Figs 11 and 12 of the accompanying drawings comprises a base support 2g made of a flexible raffia grade UV inhibited woven polyolefin fabric sheet with the sides thereof hemmed 3. A plurality of discontinuous or discrete groups or sets of tunnels marked 10a, 10b and 10c are formed on the base support with spaces marked 11 between the groups of the tunnels. Each of the tunnels is formed as described earlier with reference to Figs 1 to 3. 12 is a top flexible raffia grade UV inhibited woven polyolefin fabric sheet hemmed at the sides and placed over the groups of tunnels and fixed at the sides to the sides of the base support by one of the modes of fixing as described above except where the spaces 12 appear so that the spaces 11 between the groups of tunnels against the top sheet also provide access for the forks of a forklift or for slinging or strapping for handling loads. The pallet thus provides entry for forks or for slinging
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from different sides and directions of the pallet. The tunnels also provide certain amount of rigidity and strength to the pallet.
The pallet lh as illustrated in Figs 13 to 15 of the accompanying drawings comprises two rows of discrete tunnels 13a, 13b and 13c formed at opposite ends across the width of the base support 2h. A pair of tunnels 14a and 14b are formed along the length of the base support between the rows of discrete tunnels 13a, 13b and 13c aligned with the open spaces 15 between the discrete tunnels. The tunnels 14a and 14b can be accessed from the front side or back side of the pallet for forks entry or for slinging via the respective open spaces 15. Alternatively the forks entry for the tunnels or entry for slinging in the two rows of discrete tunnels can be from opposite sides of the pallet. Besides facilitating forks entry or entry for slinging from all the four sides of the pallet, the tunnels also provide reinforcement to the pallet. The tunnels are made as described earlier. The pallet li as illustrated in Figs 16, 17 and 18 of the accompanying drawings comprises a base support 2i made of a flexible raffia grade UV inhibited woven polyolefin fabric sheet with the sides thereof hemmed 3. The pallet also comprises three rows of vertically disposed double walled tunnels 16a, 16b and 16c formed underneath the base support in spaced apart relationship with one another. Each of the tunnels is formed with raffia grade UV inhibited woven polyolefin fabric strips folded into double walled hollow members and fixed together by one of the modes of fixing described earlier. The upper ends of the hollow members are fixed to the bottom surface of the base support by one of the modes of fixing described earlier. Each of the tunnels comprises a cellulose paper tube inserted in the space between the double walls thereof and fixed to the walls of the tunnels by one of the modes of fixing described above. Preferably each of the cellulose paper
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tubes comprises a used yarn spool cut across the length thereof. The tunnels provide flexibility to engage the forks (not shown) of a forklift (not shown) from below the pallet in the vertical direction and handle the load on the pallet. The tunnels can be accessed both from the X and Y directions in Fig 16. The pallet also can be strapped and handled by engaging the open spaces 17 and 18 between the tunnels in the X direction and in Y direction, respectively. The tunnels also provide rigidity to the pallet. The pallet of Figs 16 to 18 may comprise two sheets as in the case of the pallet of Figs 4 and 5 and may include eyelets as in the case of the pallet of Fig 8.
The following experimental examples are illustrative of the invention but not limitative of the scope thereof:
10 pallets of Figs 1 and 2 were fabricated with woven raffia grade polypropylene fabric sheet of mass 230 GSM, length 1025 mm and width 1025 mm. Fabric overflow on all the sides of the sheet was 25 mm and all the sides were provided with Herackle or over-edging stitch (hemmed). Two spaced apart double walled tunnels were formed on the base support using two woven raffia grade polypropylene fabric strips. Inner and outer fabrics of the tunnels each was 230 GSM. The tunnels were stitched by double needle chain stitch using 6000 Denier thread. Used yarn spools cut half along the length thereof were inserted between the walls of the tunnels. The tubes were stitched to the tunnels by needle chain stitch using 4000 Denier thread. The length, diameter and thickness of the tubes were 187.5 mm, 125 mm and 75 mm. The pallets were used 3 times to handle loads of 2200 kg over a period of 4 weeks and the pallets were still found to be intact and reusable.
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5 pallets of Figs 4 and 5 were fabricated with two woven raffia grade polypropylene fabric sheets of 230 GSM. The length and width of the sheets were 1175 mm and 1135 mm, respectively. Fabric overflow on all the sides of the sheets were 25 mm and all the sides were hemmed with over-edging stitch. The sheets were held together with double needle chain stitch in two rows with 6000 denier thread. The tunnels were fabricated as described earlier. Using the pallets, weights of 2200 kg were handled 6 number of times over a period of 4 weeks. The pallets were still in good condition and were found to be reusable.
Pallets of Figs 11 and 12 were fabricated with woven raffia grade polypropylene fabric sheets of 180 GSM both as base sheet and top sheet. The sheets had a length of 1175 mm and width of 1135 mm. Fabric overflow on all the sides of the sheets were 25 mm and all the sides of the sheets were hemmed with over-edging stitch. The sheets were held together at the sides with double needle chain stitch in two rows with 6000 denier thread. The discrete tunnels were formed on the base support with woven raffia grade polypropylene fabric strips of 180 GSN as described earlier. Loads of 450 kg were handled with the pellets 6 number of times over a period of 6 weeks. The pallets were found to be still intact and reusable.
The various flexible pallets of the invention as illustrated in the accompanying drawings are advantageously used, especially during loading and unloading of loads by supporting the loads only on the pallets and handling the pallets with a forklift or similar lifting mechanism without the use of wooden pallets. Instead of using the forklift or similar lifting mechanism for handling the load on the pallet, the load on the pallet also can be handled by engaging straps (wire ropes or strings) through the
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eyelets or through the spaces between the tunnels or through the tunnels. The loads can be lifted by holding the straps manually or by holding the straps with a lifting mechanism like forklift. Because of the flexible nature of the pallets, the pallets will contour or bend or fold over the loads so as to hold the loads securely and safely in place while being handled. As a result, accidents during handling of the loads are avoided and handling of the load is made easy and convenient. This can be particularly advantageous, especially in the case of flexible loads like bags or flexible containers. The pallet is foldable, mechanically strong, reusable, weather and UV resistant, fungal / insect resistant and durable. Because of the use of raffia grade polyolefin, the pallet is recycleable and does not cause disposal problems. It is ecofriendly as it does not deplete natural resources like trees as in the case of wooden pallets. It is easy to fabricate and does not require any energy for its fabrication. It is flat, compact and light weight and requires reduced space for storage and transportation. It does not significantly add to the height or weight of the load. Because of its flexibility it can also be folded during storage and transportation. As a result, storage space and transportation cost are reduced. Reuse of used yarn spools in the tunnels renders it further economical. As the cellulose paper tubes are fully enclosed within the tunnel walls, the paper tubes are not affected by moisture or water. Consequently the life of the pallet is also increased. The cellulose paper tubes help to maintain the shape of the tunnels without deforming or collapsing so that there is easy accessibility to the forks of the forklift or similar lifting mechanism in the tunnels or for the straps. The cellulose paper tubes also provide certain amount of rigidity and mechanical strength to the tunnels and base support, particularly in the case of the pallets of Figs 9 and 10, 11 and 12, 13 to 15 and 16 to 18. As a result, loads can be held on the pallet without allowing the pallet to sag excessively. Also
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heavier loads can be handled by the pallet. The pallet can be accessed for handling for different directions. The pallet is versatile as it can handle loads of different shapes and kinds and from different directions. It is user friendly and comprises few component parts and is economical. The hemming or fabric overflow at the sides of the sheet(s) helps to prevent damage to the pallets at the sides thereof and increases the structural strength of the pallets.
The above embodiments of the invention are by way of examples and should not be construed and understood to be limiting the scope of the invention. There can be variations in the arrangement of tunnels on the base support. The base support geometry can be different. The number of eyelets can vary. Instead of eyelets other strapping means like rings or loops or lugs can be provided. There can be three or more fabric sheets for the base support. The top sheet of Figs 11 and 13 may comprise multiple sheets. Embodiments comprising such variations of the invention are obvious to those skilled in the art and are to be construed and understood to be within the scope of the invention.

We claim :
1) A flexible raffia grade polyolefin fabric sheet pallet for handling a load, the pallet comprising a base support having a mass of 180 to 240 grams per square meter and comprising atleast one raffia grade UV inhibited woven polyolefin fabric sheet having the sides thereof hemmed, the pallet further comprising atleast two horizontally disposed double walled tunnels formed on the base support, each of the tunnels being formed with raffia grade UV inhibited woven polyolefin fabric strips folded into double walled hollow members and fixed on the base support and having one or more cellulose paper tubes or cellulose paper tubes halved along the length thereof inserted in the space between the double walls of each of the hollow members in close contact with one another or in spaced apart relationship with one another and optionally fixed to the walls of the hollow members.
2) The flexible pallet as claimed in claim 1, which comprises a plurality of strapping means.
3) The flexible pallet as claimed in claim 2, wherein the strapping means comprises an eyelet.
4) The flexible pallet as claimed in any one of claims 1 to 3, wherein the one or more cellulose paper tubes each comprises a used yarn spool or the one or more cellulose paper tubes halved along the length thereof each comprises a used yarn spool cut half across the length thereof.

5) The flexible pallet as claimed in any one of claims 1 to 4, wherein the base support is square or rectangular shaped.
6) The flexible pallet as claimed in anyone of claims 1 to 5, which comprises two tunnels formed on the base support in spaced apart relationship with each other.
7) The flexible pallet as claimed in any one of claims 1 to 5, which comprises a plurality of tunnels formed on the base support adjacent to one another.
8) The flexible pallet as claimed in anyone of claims 1 to 5, which comprises a plurality of discrete sets of tunnels formed on the base support in spaced apart relationship with one another and a top raffia grade UV inhibited woven polyolefin fabric sheet disposed over the tunnels and fixed to the base support at the sides thereof.
9) The flexible pallet as claimed in anyone of claims 1 to 5, which comprises two rows of discrete tunnels formed at opposite ends of the base support and a pair of tunnels extending between the two rows of discrete tunnels aligned with the spaces between the discrete tunnels.
10) The flexible pallet as claimed in anyone of claims 1 to 9, which is made of raffia grade UV inhibited polypropylene having MF1 of 2.0 to 5.0 G/10 min and xylene solubility of 2.8 to 3.4%.

11) The flexible pallet as claimed in anyone of claims 1 to 9, which is made of raffia grade UV inhibited polyethylene having MFl of 0.8 to 13 G/10 min and density of 0.951 to 0.555 G/CC.
12) A flexible raffia grade polyolefin fabric sheet pallet for handling a load, the pallet comprising a base support having a mass of 180 to 240 grams per square meter and comprising atleast one raffia grade UV inhibited woven polyolefin fabric sheet having the sides thereof hemmed, the pallet further comprising atleast two vertically disposed double walled tunnels formed underneath the base support, each of the tunnels being formed with raffia grade UV inhibited woven polyolefin fabric strips folded into double walled hollow members and fixed to the bottom surface of the base support at one ends thereof and having a cellulose paper tube inserted in the space between the double walls of each of the hollow members and optionally fixed to the walls of the hollow members,
13) The flexible pallet as claimed in claim 12, which comprises a plurality of strapping means.
14) The flexible pallet as claimed in claim 13, wherein the strapping means comprises an eyelet.
15) The flexible pallet as claimed in any one of claims 12 to 14, wherein the cellulose paper tube comprises a used yarn spool or a used yarn spool cut half across the length thereof.
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16) The flexible pallet as claimed in any one of claims 12 to 15, wherein the base support is square or rectangular shaped.
17) The flexible pallet as claimed in anyone of claims 12 to 16, which comprises two rows of discrete tunnels formed across the base support at the opposite ends thereof and two tunnels formed along the base support in the space between the two rows of discrete tunnels aligned with the spaces between the discrete tunnels.
18) The flexible pallet as claimed in anyone of claims 12 to 17, which is made of raffia grade UV inhibited polypropylene having MFl of 2.0 to 5.0 G/10 min and xylene solubility of 2.8 to 3.4%.
19) The flexible pallet as claimed in anyone of claims 12 to 17, which is made of raffia grade UV inhibited polyethylene having MFl of 0.8 to 13 G/10 min and density of 0.951 to 0.555 G/CC.
20) A flexible raffia grade polyolefm fabric sheet pallet for handling a load, the pallet
comprising a base support made of atleast one raffia grade UV inhibited woven
polyolefm fabric sheet having the sides thereof hemmed and further comprising
composite building blocks each consisting of raffia grade UV inhibited woven
polyolefm fabric and hard paper tube(s).
Dated this 12th day of May 2009
(Jose M A)
ofKhaitan&Co
Agent for the Applicants
" .13 MAY 20091'