Compression molded double wall blocks for a pallet and associated methods

A compression molding system comprising:

• a first extruder configured to output melted plastic;
• a second extruder downstream from said first extruder and configured to mix the melted plastic with wood chips to output a composite material;
• a transfer valve downstream from said second extruder, wherein the transfer valve alternately switches between an inner block output and an outer block output, so as to direct the composite material to a single one of these outputs at any time;
• at least one inner block assembly comprising:
• at least one inner block mold to receive the composite material from the inner block output associated with said transfer valve, and
• at least one inner block press aligned with said at least one inner block mold, and configured to press the composite material in the at least one inner block mold into a desired shape of at least one inner block having an opening on one side;
• at least one outer block assembly comprising:
• at least one outer block mold to receive the composite material from the outer block output associated with said transfer valve, and
• at least one outer block press aligned with said at least one outer block mold, and configured to press the composite material in the at least one outer block mold into a desired shape of at least one outer block having an opening on one side;
• and
• a press assembly downstream from said at least one inner and outer block assemblies, and configured to press one of the at least one inner blocks into the opening in one of the at least one outer blocks to form a double wall block;
• a robot arm positioned between said inner and outer block mold assemblies, and configured to alternately grab the at least one inner block and the at least one outer block as they exit the at least one inner and outer block molds;
• an inner block conveyor positioned between said robot arm and said press assembly, and configured to receive the at least one inner block from said robot arm;
• and
• an outer block conveyor adjacent said inner block conveyor and positioned between said robot arm and said press assembly, and configured to receive the at least one outer block from said robot arm,
• wherein:
• the inner block output directs the composite material to the at least one inner block mold and the outer block output directs the composite material to the at least one outer block mold;
• and
• said press assembly is configured to receive the at least one inner block and the at least one outer block from said inner and outer block conveyors.