Nestable Pallet
A pallet includes a platform having a plurality of openings for carrying an object thereon, and a plurality of legs attached to the platform for supporting the platform above a surface. Each of the legs is positioned in a respective one of each of the platform openings and includes a cone having an upper end proximate the platform and a lower end for resting on the surface. The upper end has a diameter greater than a diameter of the lower end so that a second like pallet can be nested within the first pallet. Each leg can include a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet in order to facilitate separation of the second pallet from the first pallet.
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This application claims priority to U.S. Provisional Application No. 60/747,626, filed May 18, 2006.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTIONThe invention relates to pallets for supporting objects and methods for making same. One pallet according to a preferred embodiment of the invention has conical legs that allow for one pallet to be stacked on and nested within another pallet. The legs are made of paper and include a feature that facilitates the separation of nested pallets. Another preferred embodiment of the invention includes a pallet that can be made from a single piece of corrugated paper.
There exists a wide variety of portable pallets for transporting and storing packages and materials, such as in factories, warehouses and vehicles. Nestable pallets are particularly useful in that they allow multiple pallets to be stacked on and nested within each other when they are not carrying any materials. This facilitates movement of the empty pallets and minimizes the space they occupy during transport and storage.
A number of nestable pallets are known. For example, U.S. Pat. No. 5,730,067 to Kohlhaas discloses a nestable pallet comprising an apertured single deck with a number of leg members configured as hollow truncated cones. The deck can be constructed of heavy paper board, corrugated cardboard, wood or plywood, and the legs are made of steel sheet metal or hard plastic. The legs are open at the top, and closed off at the bottom by a generally flat bottom section.
SUMMARY OF THE INVENTIONIt is an object of the present invention to provide a pallet that can be made of paper, and is capable of carrying substantial loads.
It is another object of the present invention to provide a nestable pallet with legs that can be made of paper that are open at both ends.
It is yet another object of the present invention to provide a pallet that can be nested with another pallet and easily separated from the other pallet.
It is yet another object of the present invention to provide a pallet that can be made of a single sheet of material, such as corrugated paper.
These and other objects of the present invention are achieved in the preferred embodiments of the invention described below. One of the preferred embodiments of the invention includes a pallet having a platform with a plurality of openings for carrying an object thereon, and a plurality of legs attached to the platform for supporting the platform above a surface. Each of the legs is positioned in a respective one of each of the platform openings and includes a cone having an upper end proximate the platform and a lower end for resting on the surface. The upper end having a diameter greater than a diameter of the lower end such that a second like pallet can be nested within the first pallet, and the leg includes a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet to facilitate separation of the second pallet from the first pallet.
According to another preferred embodiment of the invention, the platform includes a plurality of foldable sections positioned proximate the platform openings for providing a surface area contacting the legs, in which the legs are attached to the platform by an adhesive contacting the legs and the surface area of the foldable sections.
According to yet another preferred embodiment, a pallet includes a platform having an upper surface, a lower surface, and a plurality of openings therethrough, and a plurality of legs attached to the platform for supporting the platform above a surface, in which each of the plurality of legs is positioned in a respective one of the platform openings. Each leg includes an outer cone having an upper end proximate the platform and a lower end for positioning on the surface. The upper end defines a diameter greater than a diameter defined by the lower end, and an inner cone is positioned within the outer cone and has an upper end proximate the platform and a lower end opposite the upper end. The upper end defines a diameter greater than a diameter defined by the lower end.
According to another preferred embodiment of the invention, each of the plurality of legs includes a first flared section proximate the upper end of the inner cone and attached to the upper surface of the platform, and a second flared section proximate the upper end of the outer cone and attached to the lower surface of the platform. An area of the platform that defines each of the plurality of openings is sandwiched between the first flared section and the second flared section of each of the legs.
According to another preferred embodiment of the invention, the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower section of the inner cone.
According to another preferred embodiment of the invention, the pallet is made of paper.
According to another preferred embodiment of the invention, the inner cone is sloped at an angle less than the outer cone.
According to another preferred embodiment of the invention, the inner cone is sloped at an angle of about eight degrees, and the outer cone is sloped at an angle of about ten degrees.
According to another preferred embodiment of the invention, the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower end of the inner cone.
According to another preferred embodiment of the invention, an outer surface of the inner cone is attached to an inner surface of the outer cone by an adhesive.
Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which;
A pallet according to a preferred embodiment of the invention is illustrated in
The platform 12 is formed of double wall corrugated paper having a thickness of 6.5 mm, with nine openings 14 for receiving the legs 22. Each opening 14 has a diameter of 95 mm.
As shown in
An adhesive, such as polyvinyl acetate (PVA) glue is sprayed or spread around the outer rim of the large diameter end 24 of the legs 22. The legs 22 are then pushed down through the openings 14. As shown in
As shown in
As shown in
In addition to facilitating separation of nested pallets 10, 10′, the bull nose 28 also adds radial and axial strength to the leg 22, which compensates for the absence of a bottom panel in the leg 22, enabling the pallet 10 to withstand heavier loads. Preferably, the pallet 10 can support an evenly distributed mass of about 600 kg. Furthermore, the bull nose 28 provides a smooth surface at the bottom of the leg 22 that facilitates sliding movement of the pallet 10 on a supporting surface such as the ground or floor.
A pallet according to another preferred embodiment of the invention is illustrated in
Each cone 122a, 122b has flared portions 123a, 123b, respectively, extending outward from the large diameter ends 124a, 124b of the cones 122a, 122b. An adhesive, such as polyvinyl acetate (PVA) glue, is sprayed or spread onto the flared portion 123a of the outer cone 122a, which is then pressed on the lower surface of the platform 112 of the pallet 100. Adhesive is sprayed at the inner surface of the small diameter end 126a of the outer cone 122a within the area between the bull nose 128a and the sidewall of the cone 122a. Adhesive is placed on the flared portion 123b of the inner cone 122b, and the inner cone 122b is positioned on top of the outer cone 122a, such that the flared portion 123b of the inner cone 122b rests on the upper surface of the platform 112. The small diameter end 126b of the inner cone 122b contacts the adhesive in the crevice of the bull nose 128a of the outer cone 122a to adhere the outer cone 122a and the inner cone 122b together. The inner cone 122b does not have a bull nose.
As shown in
As shown in
The pallet 100 can be made of corrugated paper, or other suitable material including moisture resistant paper board. It should be noted that the term “paper” as used throughout this application refers generally to all kinds of paper, including cardboard.
A pallet according to another preferred embodiment of the invention is illustrated in
The platform 212 has a top side 213 for carrying objects, and an under side 214 opposite the top side 213. While the platform 212 is preferably rectangular as shown in
As shown in
The first and second leg members 201, 202 each have four walls 201a-d, 202a-d, respectively. The third leg member 203 has a total of five walls 203a-e. While the leg members 201, 202, 203 are preferably rectangular, they can be a variety of shapes, such as conical, triangular or other polygonal shape. In addition, the number of leg members can be varied.
The first walls 201a, 202a, 203a of the leg members 201, 202, 203 lie flat on the under side 214 of the platform 212. The second walls 201b, 202b, 203b extend perpendicularly from the first walls 201a, 202a, 203a and the third walls 201c, 202c, 203c extend perpendicularly from the second walls 201b, 202b, 203b. The fourth walls 201d, 202d, 203d extend perpendicularly from the third walls 201c, 202c, 203c back toward the underside 214 of the platform 212. The fifth wall 203e of the third leg member 203 extends perpendicularly from the fourth wall 203d and lies parallel to and flat on the first wall 203a.
Each of the leg members 201, 202, 203 can have a pair of rectangular openings 205 formed in the second and fourth walls 201b, 201d, 202b, 202d, 203b, 203d of the leg members 201, 202, 203 and aligned on a horizontal axis that is substantially parallel with the platform 212. As such, fork-lift forks can be inserted through the openings 205 to engage and lift the pallet 200. Furthermore, the pallet 200 can be accessed by fork-lift forks from all four sides of the pallet by either inserting the fork-lift forks through the openings 205 in the leg members 201, 202, 203, or by insertion of forks in the space 221 between the first and third leg members and the space 223 between second and third leg members.
Each of the leg members 201, 202, 203 can have a plurality of openings 206 formed on the third wall 201c, 202c, 203c of the leg members 201, 202, 203. A support member, such as a conical paper tube 207, can be positioned within each of the openings 206. The tubes 207 are positioned within the openings 206 of the leg members 201, 202, 203 such that the tubes 207 reside in perpendicular relation to the platform 212, as shown in
The leg members 201, 202, 203 can be positioned directly on a ground surface and thereby support the platform 212 above the ground surface. Alternatively, the leg members 201, 202, 203 can be mounted on a substantially flat base member 220, as shown in
A preferred method of making the pallet 200 is illustrated in
As shown in
As shown in
The third leg member 203 is a separate piece that can be attached at the center for the sheet 222 between the first end 215 and second end 216. As shown in
When the first and second leg members 201, 202 have been formed, the perforated sections 225 can be partially detached therefrom to form flaps that can be folded inwardly into the leg members 201, 202 to form the openings 205, shown in
A pallet according to yet another preferred embodiment of the invention is illustrated in
The platform 312 has a top side 313, shown in
Each of the three leg members 301, 302, 303 are rectangular, and extend across the width of the platform 312, as shown in
The first walls 301a, 302a, 303a of the leg members 301, 302, 303 lie flat on the under side 314 of the platform 312. The second walls 301b, 302b, 303b extend perpendicularly from the first walls 301a, 302a, 303a and the third walls 301c, 302c, 303c extend perpendicularly from the second walls 301b, 302b, 303b. The fourth walls 301d, 302d, 303d extend perpendicularly from the third walls 301c, 302c, 303c back toward the underside 314 of the platform 312, as shown in
The platform 312 includes wing sections 315a, 316a at opposite ends 315, 316, respectively, as shown in
Each of the leg members 301, 302, 303 can have a plurality of openings 306 formed on the third wall 301c, 302c, 303c of the leg members 301, 302, 303. A support member, such as conical paper tubes 307, can be positioned within the openings 306. The tubes 307 are positioned within the openings 306 of the leg members 3011 302, 303 such that the tubes 307 reside in perpendicular relation to the platform 312, as shown in
The leg members 301, 302, 303 can be positioned directly on a ground surface and thereby support the platform 312 above the ground surface. Alternatively, the leg members 301, 302, 303 can be mounted on a substantially flat base member 330, as shown in
A preferred method of making the pallet 300 is illustrated in
As shown in
As shown in
An adhesive can be applied to the sheet 322 to attach wall 301a thereto, as shown in
The third leg member 303 is a separate piece that can be attached at the center for the sheet 322 between the first end 315 and second end 316 of the platform 322. The third leg member 303 can be held in place on the sheet 322 by an adhesive 340 placed on the first wall 303a of the leg member 303 or the sheet 322. Alternatively, other attachment means can be employed such as staples, nails or other fasteners.
Yet another alternative embodiment of the invention is illustrated in
A pallet according to yet another embodiment of the invention is illustrated in
A pallet and methods for making same are disclosed above. Various embodiments of the invention can be made without departing from its scope. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation—the invention being defined by the claims.
Claims
1. A pallet comprising:
- (a) a platform having a plurality of openings for carrying an object thereon;
- (b) a plurality of legs attached to the platform for supporting the platform above a surface, wherein each of the legs is positioned in a respective one of each of the platform openings and comprises: (i) a cone having an upper end proximate the platform and a lower end for resting on the surface, (ii) the upper end having a diameter greater than a diameter of the lower end whereby a second like pallet can be nested within the first pallet, and (iii) and further wherein the leg includes a bull nose positioned proximate the lower end for providing a stop for the second like pallet nested within the first pallet to facilitate separation of the second pallet from the first pallet.
2. A pallet according to claim 1, wherein the platform comprises a plurality of foldable sections positioned proximate the platform openings for providing a surface area contacting the legs, wherein the legs are attached to the platform by an adhesive contacting the legs and the surface area of the foldable sections.
3. A pallet comprising:
- (a) a platform having an upper surface, a lower surface, and a plurality of openings therethrough; and
- (b) a plurality of legs attached to the platform for supporting the platform above a surface, wherein each of the plurality of legs is positioned in a respective one of the platform openings and comprises: (i) an outer cone having an upper end proximate the platform and a lower end for positioning on the surface, the upper end defining a diameter greater than a diameter defined by the lower end, and (ii) an inner cone positioned within the outer cone and having an upper end proximate the platform and a lower end opposite the upper end, the upper end defining a diameter greater than a diameter defined by the lower end.
4. A pallet according to claim 3, wherein each of the plurality of legs includes:
- (a) a first flared section proximate the upper end of the inner cone and attached to the upper surface of the platform;
- (b) a second flared section proximate the upper end of the outer cone and attached to the lower surface of the platform; and
- (c) wherein an area of the platform defining each of the plurality of openings is sandwiched between the first flared section and the second flared section of each of the legs.
5. A pallet according to claim 3, wherein the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower section of the inner cone.
6. A pallet according to claim 3, wherein the pallet is made of paper.
7. A pallet according to claim 3, wherein the inner cone is sloped at an angle less than the outer cone.
8. A pallet according to claim 7, wherein the inner cone is sloped at an angle of about eight degrees, and the outer cone is sloped at an angle of about ten degrees.
9. A pallet according to claim 7, wherein the lower end of the outer cone of each of the legs includes a bull nose defining an area that receives the lower end of the inner cone.
10. A pallet according to claim 7, wherein an outer surface of the inner cone is attached to an inner surface of the outer cone by an adhesive.
Type: Application
Filed: Jan 22, 2007
Publication Date: Nov 22, 2007
Applicant: CONITEX-SONOCO, LLC (Gastonia, NC)
Inventors: David Wesley Monteith (Charlotte, NC), Jean Francois Ruffet (Gastonia, NC)
Application Number: 11/625,557