Three-piece lightweight glueless pallet

Abstract

A three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels of essentially rectangular configuration, with a plurality of longitudinally disposed structural members created on the inner surface of each panel. During the creation of a basic pallet member, one of the panels is turned such that its structural members are disposed in an angular relationship to the structural members of the other of the panels. A spaced plurality of slots are formed in the structural members of each basic panel member, with such slots in the structural members of one panel positioned to coincide with the slots of the structural members of the other panel, so that when the two panels are aligned and pushed together, the slots of the structural members of one panel enter and interfit with respective slots of the other panel. The interfitted panels, upon thereafter being placed inside an encapsulating member constructed of lightweight material, form an integral, three-piece pallet unit of considerable strength. Preferably the plurality of longitudinally disposed structural members are made up of separate, longitudinally extending legs whose inner surfaces have been secured together either by adhesive means or by mechanical means. Generally rectangularly shaped apertures are provided in the basic pallet member that are intended to receive the forks of a fork lift truck, which apertures align with similar apertures in said encapsulating member at such time as latter member is installed around said basic pallet member.

Description

BACKGROUND OF THE INVENTION

[0001] It is well known that pallets, typically made of oak boards nailed to several spaced apart structural oak members called stringers, are in extensive use for shipping merchandise, raw materials and the like. These pallets are used not only in the United States, but in almost all of the industrial nations of the world as well. The spacing of the structural oak members or stringers is such as to define between such members, insert locations or apertures into which the forks of a forklift truck can extend, so that the pallet, along with the merchandise or cargo stacked thereon, can be readily moved from one location to another. The use of these pallets makes it possible to move the merchandise or cargo between destination points without it being necessary to unload and then reload.

[0002] Although these oak pallets are not particularly expensive to make, typically being constructed from rough oak planking, they are quite heavy, weighing on the order of 40 pounds apiece. It is obvious that if literally dozens of pallets upon which merchandise or cargo has been stacked are loaded upon a cargo aircraft for delivery to a remote location, there is a sizable weight penalty to be paid.

[0003] Also as a consequence of the weight of the oak pallets, it is often not feasible to try to recycle the pallets, so they frequently are taken to a dump site for destruction or to become part of a landfill. Because of the large number of pallets being discarded worldwide, it is a fact that at many landfill locations, a penalty or surcharge on a perpallet basis is imposed.

[0004] It has been found that most of the items shipped commercially on pallets do not need or require the considerable strength afforded by hardwood used in constructing pallets of conventional configuration, and various attempts have been made to create hardwood pallets that are lighter than the 40 pound pallets conventionally used. However, it was found that if the size of the stringers is diminished too much, it becomes difficult to drive nails into the stringers, and furthermore, the nails often tend to pop out and not hold. In other words, it has not proven possible to reconfigure oak pallets so as to markedly diminish their weight without seriously diminishing their usability and durability. Because of this fact it is correct to say that the typical hardwood pallet is overbuilt for 90% of the loads that are placed on it.

[0005] The Moore U.S. Pat. No. 4,228,744 entitled “Pallet Formed From Two Spaced, Interlocking Sheets of Corrugated paperboard and Rigid Sleeves” relates to a pallet formed of paperboard material, such as two sheets of corrugated paperboard which are cut to define interlocking tabs spaced in parallel relationship. However, the Moore pallet is designed for use with only very light loads, and his design would be entirely insufficient insofar as serving as a substitute for a conventional oak pallet.

[0006] The Ogilvie, Jr. et al U.S. Pat. No. 6,029,582 entitled “Force Resisting Corrugated Assembly” represented an improvement in the field of lightweight pallets not requiring the use of wood, with this invention involving upper and lower components assembled by the use of locking slots. The Ogilvie et al invention offers a disposable pallet that on the one hand can be recycled but on the other hand that offers strength and durability. In its preferred embodiment, glue or other adhesive for securing the upper and lower components together, but unfortunately, the need for glueing the upper and lower components together represented a step either requiring the painstaking application of glue or else necessitating the design of a complex machine. It was obvious that if the need for glueing the components together could be avoided, this would be a step forward.

[0007] It is obvious that a continuing need exists for a highly satisfactory lightweight, low cost pallet requiring no use of glue, and it is the purpose of this invention to provide such a pallet.

SUMMARY OF THE INVENTION

[0008] In accordance with this invention we have provided a pallet of unique design, with it being possible in accordance with this teaching to create without the use of glue, a lightweight pallet of corrugated paperboard or similar material, with this pallet being sufficiently strong for most purposes. Through rigorous testing we have established that our novel design meets the need for a pallet enabling merchandise or cargo to be transported to distant locations without having to pay the considerable weight penalty necessarily involved when conventional oak pallets are used.

[0009] In the primary embodiment, our novel pallet involves the use of a basic pallet member utilized in conjunction with an encapsulating member. The basic pallet member is constructed from a pair of die cut panels of generally rectangular configuration. On the inner surface of each panel we have created, by folding, a plurality of parallel, longitudinally disposed structural members. Each of the longitudinally disposed structural members is suitably slotted in a plurality of locations, making it possible for a pair of generally similar panels to be joined together in a relationship in which the structural members of one panel are disposed at an angle, preferably at a right angle, with the structural members of the other panel.

[0010] Although a lightweight pallet formed of these joined together panels represents an entity possessing considerable strength, it is entirely possible that during use, the upper and lower panel members might tend to separate. Accordingly, it is has been customary in the past to apply glue or other adhesive to inner abutting edges of the two panels, so that when the panels have been assembled in an operative relationship, a very strong unit is formed that is not likely to come apart.

[0011] Unfortunately, the need to apply glue or other adhesive to the inner abutting edges of the upper and lower panels causes a considerable increase in cost. This is because that either additional labor is required for the application of the glue, or else it is necessary to resort to a machine design such that glue is automatically applied at appropriate locations to the inner surfaces of the members to be joined together. However, to design this capability into a pallet making machine necessarily causes a great increase in the cost and complexity of the machine.

[0012] Therefore, we have evolved a highly advantageous design in which the upper and lower panel members, instead of being glued together, are only tightly interfitted together to form a basic pallet member, with this thereafter being followed by placement of the basic pallet member into a lightweight encapsulating member, preferably of corrugated paperboard.

[0013] The encapsulating member can be of relatively simple construction, configured to receive the basic pallet member in what may be regarded as a central position of the encapsulating member. The encapsulating member is provided with flaps to be wrapped around the basic pallet member, with tabs or protrusions created upon the encapsulating member that are designed to be inserted into a pair of slots provided in an upper surface of the basic pallet member. Upon the insertion of the tabs or protrusions into the slots in the basic pallet member, the encapsulating member is essentially locked in a surrounding relationship to the basic pallet member. In this way, a highly versatile, three-piece lightweight pallet has been created in which no requirement exists for the glueing of any of the various members together.

[0014] With regard to the creation of the basic pallet member by the use of the previously mentioned die cut corrugated paperboard members, it is to be noted that we prefer to create on each member, several groups of scoring lines, with all of these scoring lines being in a spaced, parallel relationship. We can use a wide range of materials in the creation of the basic pallet members, ranging from light test single wall corrugated paperboard such as 200 pound test Cflute, up to a heavy grade triple wall corrugated paperboard such as 1200 pound test triple wall material. In many instances we prefer the use of 350 pound test, double wall corrugated paperboard in the construction of the novel panel members, but we are not to be limited to corrugated paperboard, for we can use a wide range of other materials, as long as such other material can be cut and scored and then folded in the manner described herein.

[0015] In the creation of each panel to be folded, we utilize closely grouped scoring lines, involving at least one centrally-disposed line. It is possible for the material of the panel at the location of the centrally-disposed scoring line to be moved upwardly or downwardly out of the plane of the panel at such time as the distance between the ends of the panel is caused to decrease. In this manner, a narrow, elongate leg is created on each side of the centrally-disposed scoring line.

[0016] Although in accordance with this invention no glue or cement is required for use between each pair of adjacent, equally sized legs, each pair of elongate, narrow adjacent legs nevertheless become relatively rigid in a form we prefer to regard as a longitudinally disposed structural member that is disposed perpendicular to the plane of the panel. We may utilize glue, mechanical means, or other arrangement for assuring the rigidity of the longitudinally disposed structural members of each panel. The mechanical means may include staples, or an interlocking tab arrangement typically involving one or more interlocking tabs created on one leg of a longitudinally disposed structural member, and corresponding tab-receiving slots on the other leg of the structural member.

[0017] It is to be understood that by configuring each generally rectangularly shaped panel so as to create several groups of scoring lines, it becomes readily possible, at the time the distance between the ends of the panel is caused to decrease, to create a parallel array of these longitudinally disposed structural members. By creating each group of scoring lines in a properly spaced relationship with other groups of scoring lines, a desirably stiff lightweight panel can be created, and in a spacing congruent with the spacing of the forks of a forklift truck.

[0018] By then selecting a second panel of like construction, and securing it to the first panel in such a manner that the longitudinally disposed structural members of the two panels are in an angular relationship, such as a right angle relationship, it is possible to create a highly versatile basic pallet member having a high strength to weight ratio. It is to be understood that we prefer for the two panels to be joined in an orthogonal relationship, but we are not to be limited to this. We also prefer for the longitudinally disposed structural members to be created perpendicular to the corrugations, but this is not a requirement.

[0019] Although not quite as strong as a conventional oak pallet, our novel lightweight, glueless pallet is nevertheless sufficiently strong for most purposes, and quite advantageously, we can in some instances employ a number of different techniques for incorporating certain stiffening into the basic pallet member when particularly heavy loads are to be carried.

[0020] A highly effective securing together of the two panels residing in an angular relationship is made possible by providing appropriately spaced slots or notches in the longitudinally disposed structural members of both panels, with this slotting taking place at the locations where the longitudinally disposed structural members of one panel intersect with the longitudinally disposed structural members of the other panel. The depth of these slots is such that the panels can be interfitted together with the crests of the series of longitudinally disposed structural members of each panel residing in firm contact with the undersurface of the other panel. Instead of applying glue to the panels utilized in the creation of the basic pallet member, we can thereafter encapsulate the basic pallet member by the use of a simple and inexpensive overwrap of corrugated paperboard. In this way we can create a pallet that is strong, inexpensive, and of light weight, typically weighing less than one-fifth of the weight of an oak pallet of comparable size and weightcarrying ability.

[0021] It may be noted that the longitudinally disposed structural members created on each panel of the basic pallet member bear a slight relationship to an I-beam of the type used in the creation of buildings, and inasmuch as the crests of the longitudinally disposed structural members intrinsic to each panel are in firm contact with the underside of the other panel at the time of panel joinder to form a basic pallet member, the height of the properly interfitted panels does not greatly exceed the height of each panel individually. Because the longitudinally disposed structural members of one panel are disposed in an angular relationship with the longitudinally disposed structural members of the other panel, a grid-like construction is achieved, which has a strength quite adequate for most loads, but without the severe weight penalty associated with the use of conventional oak pallets.

[0022] It is therefore a principal object of this invention to provide a lightweight, glueless three-piece pallet that can be readily sized to meet the requirements of the load to be transported, thus avoiding the limitations of a conventional hardwood pallet, which cannot be constructed economically smaller or lighter than a certain minimal size and weight.

[0023] It is another object of this invention to provide a novel lightweight three-piece pallet created from upper and lower panels placed in a particularly strong, unobvious relationship to create a basic pallet member that can be utilized inside of a precut encapsulating member of simple construction, thus entirely obviating the need for any glue or other securing means in the creation of a pallet usable with a forklift truck.

[0024] It is still another object of this invention to provide a very versatile lightweight three-piece pallet that can be readily configured such that it can be used for a wide variety of purposes, with no glue or other securing means being required in order to secure the pallet components together.

[0025] It is yet another object of this invention to provide a novel lightweight, three-piece pallet in which the configuration of the pallet can be matched to meet the load requirements of the product being shipped, so that ample strength will be provided for a particular location on the pallet where greater support is desired.

[0026] It is a further object of this invention to provide a lightweight three-piece pallet in which the upper and lower panels of the basic pallet member are constructed from lightweight material in which longitudinally disposed structural members have advantageously been created, with the longitudinally disposed structural members of one panel secured in an angular relationship, preferably an orthogonal relationship, with the longitudinally disposed structural members of the other panel, so as to create a particularly strong, gridlike structure that can be readily entered by the forks of a forklift truck.

[0027] It is a yet further object of this invention to provide a novel basic pallet member utilized in conjunction with an encapsulating member, in which both the upper and the lower panels of the basic pallet member are constructed from corrugated paperboard that has been folded in a highly effective manner so as to create a plurality of longitudinally disposed structural members arranged in a parallel relationship, with the slotted longitudinally disposed structural members of the upper panel secured without the use of glue in an interlocked angular relationship with the slotted, longitudinally disposed structural members of the lower panel, such that a strong, gridlike relationship is created.

[0028] These and other objects, features and advantages of this invention will become more apparent as the description proceeds.

BRIEF DESCRIPTION OF DRAWINGS

[0029] FIG. 1 is a perspective view of our novel three-piece lightweight pallet, which consists of a basic, two piece pallet member that is to be enclosed by a novel encapsulating member, with this arrangement making the use of glue entirely unnecessary;

[0030] FIG. 2 is a plan view in which the preconfigured encapsulating member is shown in its spread out or flattened condition in order to reveal, in considerable detail, the various scoring lines, flaps and apertures utilized in accordance with this invention;

[0031] FIG. 3 is a perspective view showing one of the steps taken in order to bring about the enclosing of the basic pallet member by the use of the encapsulating member, with it to be noted that a pair of elongate slots are provided in a central part of the upper surface of the basic pallet member;

[0032] FIG. 4 is a view generally relatable to FIG. 3 but here showing the pair of major flaps just before their respective tabs enter the pair of elongate slots provided in the upper surface of the basic pallet member;

[0033] FIG. 5 is a perspective view of a basic pallet member constructed in accordance with this invention having been enclosed by the encapsulating member, with a foreground portion of the encapsulating member having been sectioned away to reveal certain internal construction of the basic pallet member, and making clear the presence of apertures that may be entered by the forks of a fork lift truck;

[0034] FIG. 6 is a view similar to FIG. 5 but showing in greater detail an exemplary embodiment of our basic pallet member, considered apart from the encapsulating member, with the basic pallet member having been assembled from panels made of corrugated paperboard that have been folded in a highly effective manner, with these panels thereafter assembled with the longitudinally disposed structural members of one panel disposed in an angular relationship to the longitudinally disposed structural members of the other panel;

[0035] FIG. 7 is a plan view of a typical die cut panel prior to assembly with a like panel, with this view revealing the scoring lines created thereon in order to permit longitudinally disposed structural members to be created in a parallel array in accordance with this invention, with this view also depicting the commencement of folding along these scoring lines;

[0036] FIG. 8 is a plan view, with a portion fragmented away, that has been created to a similar scale as utilized in FIG. 7, with this view revealing an optional arrangement for joining adjacent legs of the longitudinally disposed structural members together, with this optional arrangement involving one or more interlocking tabs utilized on one leg of a narrow, longitudinally disposed member, and corresponding number of tab-receiving slots utilized on the other leg of the narrow, longitudinally disposed member, with each slot disposed in alignment with the corresponding interlocking tab;

[0037] FIG. 9 is a fragmentary view related to FIG. 8 and showing to a larger scale, the components of a typical interlocking tab;

[0038] FIG. 10 is a fragmentary view to a scale similar to that used in FIG. 9, revealing the wings of an interlocking tab having passed through the adjacent slot, with these wings thereafter moving back into a substantially planar relationship in order to achieve a locking of two adjacent legs together;

[0039] FIG. 11 is a plan view of an encapsulating member generally along the lines of FIG. 2 but here showing an embodiment containing suitable apertures, such that the completed pallet can be used with a pallet jack; and

[0040] FIG. 12 is a perspective view of the basic pallet member generally along the lines of FIG. 6, but here indicating the use of apertures in the lower surface of the basic pallet member that coincide with the apertures in the encapsulating member, such that the completed pallet can be effectively used with a pallet jack.

DETAILED DESCRIPTION

[0041] With initial reference to FIG. 1, it can be seen that we have depicted a first embodiment of our invention, involving a lightweight, three-piece pallet 10, comprising a basic pallet member 12 foldably constructed from a pair of generally flat, die cut panels 14 and 15. It will be noted from this figure that the basic pallet member 12 resides on a central portion of an encapsulating member 20, with the basic pallet member and the encapsulating member together presenting a sturdy, lightweight three-piece pallet advantageously requiring no glue or adhesive in its construction.

[0042] As will shortly be discussed at some length, the basic pallet member 12 has considerable strength in its own right because of each of the die cut panels 14 and 15 having been previously folded in a highly advantageous manner, so as to create two or more longitudinally disposed structural members (not clearly visible in this figure) that are intrinsic to the panel. Because of this, when the panels 14 and 15 are assembled together to form the basic pallet member 12, the longitudinally disposed structural members of one panel are intended to be disposed at an angle to the longitudinally disposed structural members of the other panel. As will be discussed hereinafter, it is preferable for the longitudinally disposed structural members of one panel to be disposed in an orthogonal (90°) relationship with the longitudinally disposed structural members of the other panel, but we are not to be limited to this.

[0043] As a result of the manner of assembly wherein the longitudinally disposed structural members of one panel meet in an angular relationship with the longitudinally disposed structural members of the other panel, when the panels are properly interfitted in a glueless manner, a high strength, grid-like structure is created. Further details of the basic pallet member 12 will be discussed in conjunction with FIG. 6, wherein longitudinally disposed structural members 140, 142, 144 and 150 are seen to be an intrinsic part of one panel, and longitudinally disposed structural members 160, 170, 180 and 190 may be seen to be an intrinsic part of the other panel of the basic pallet member.

[0044] Because of the highly advantageous manner in which the upper and lower panels are interfitted, they tend to remain in assembled relationship, but in the past it has been customary to apply glue or some other adhesive on abutting interior portions of the panel members 14 and 15, to prevent their separation during use.

[0045] In accordance with the instant invention, the use of adhesive between the panel components of the basic pallet member is made unnecessary, for the previously-mentioned encapsulating member 20 is configured to closely surround the basic pallet member 12, with tab portions contained on certain edges of the encapsulating member interfitting with narrow, elongate slots utilized on the upper surface of the basic pallet member 12. By way of example, such slots can be placed on the centerline of the basic panel member, as shown at 36 and 38 in FIG. 1. In this way it becomes readily possible to lock the encapsulating member around the basic pallet member in a very secure and stable manner so as to create a sturdy, durable, easily affordable three-piece unit suitable for many pallet applications, with the use of glue not being required.

[0046] With continued reference to FIG. 1, it will be noted that rectangular apertures are provided in a number of locations, such as the pair of apertures or openings 16 in the end of the basic pallet member 12, and the pair of apertures or openings 18 in the side of the basic pallet member 12. Comparable apertures or openings are also provided at appropriate locations in the encapsulating member 20, to permit the entry, when the three-piece pallet has been completed, of the forks utilized on the front of a fork lift truck. It is to be understood that when the encapsulating member has been folded around the basic pallet member 12, apertures or openings 76 of the encapsulating member 20 move into alignment with the apertures or openings 16, and the apertures or openings 56 of the encapsulating member move into alignment with the apertures or openings 18 of the basic pallet member. Also visible in FIG. 1 are a pair of locking tabs 26 and 28, and a pair of locking tabs 32 and 34 that are utilized on the opposite edges of the encapsulating member, which tabs are intended to enter and engage the elongate slots 36 and 38 as a final step in the enclosing of the basic pallet member 12.

[0047] In order to reveal some of the novel aspects of this invention in greater detail, reference is now made to FIG. 2, where it will be seen that we have depicted the novel encapsulating member 20 in a flattened condition, with it to be noted that the central portion 22 of this embodiment may be regarded as unbroken. By way of example, the central portion may, for one embodiment, measure approximately 40 inches by 40 inches, but in another embodiment the central portion may measure 40 inches by 48 inches, with the basic pallet member used therewith being sized accordingly. We obviously are not to be limited to these dimensions.

[0048] Prominently attached to the left edge of the central portion 22 as depicted in FIG. 2 is a large flap 24, attached to which are previously-mentioned tabs 26 and 28. Attached to the right edge of the central portion 22 is a large flap 30, attached to which are tabs 32 and 34. As will be explained in detail hereinafter, the pair of tabs 26 and 28, and the pair of tabs 32 and 34, play a prominent role in securing the large flaps 24 and 30 around the basic pallet member 12 in that those tabs are intended to enter the earlier-mentioned slots 36 and 38 provided in the upper surface of the basic pallet member 12, there to be retained in a locking relationship. The resulting pallet is sturdy, and quite unlikely to come apart in normal use.

[0049] Although it is typical for the tab-containing outermost edges of the large flaps 24 and 30 to be disposed closely together at such time as the basic pallet member has been encapsulated, it is possible for somewhat smaller flaps 24 and 30 to be utilized, so that the outermost edges are not in a touching relationship, with the result being that centermost part of the basic pallet member 12 is not enclosed. In such an instance as this, separate tab-receiving slots would be provided on the upper surface of the basic pallet member, for receiving the locking tabs of the large flaps. Understandably, the tab-receiving slots would not be disposed on the centerline of the basic pallet member 12 in this latter instance, but the large flaps would nevertheless encompass a sufficient extent of the upper portion of the basic pallet member as to create a stable and effective configuration.

[0050] Continuing with FIG. 2, it is to be understood that we provide a number of scoring lines at the time of manufacture of the encapsulating member 20, and for example, we may use scoring lines 40 and 42 at the base of large or major flap 24, with these parallel scoring lines serving to define a minor flap 44. It will be noted that rectangular openings 46 are provided, for fork-receiving purposes, between these two scoring lines.

[0051] Similarly, we may utilize scoring lines 50 and 52 at a base location of the large or major flap 30, with these parallel scoring lines serving to define a minor flap 54. It will be noted that rectangular openings 56 are disposed between these two scoring lines. As should now be clear, the rectangular openings 46 and 56 are intended to coincide with like openings provided in the basic pallet member, so as to make possible the entry of the forks of a forklift truck.

[0052] In addition to the major flaps, we also prefer to utilize a plurality of minor flaps on the encapsulating member in order to assure the retention of the basic pallet member. It will be noted in FIG. 2 that we provide scoring lines 60 and 62 at a location that may be regarded as the upper portion of the encapsulating member depicted in this figure. These parallel scoring lines serve to define a minor flap 64 in which are located a pair of rectangular openings 66. Similarly, we provide scoring lines 70 and 72 at a location that may be regarded as the lower portion of the encapsulating member depicted in FIG. 2, which serve to define a minor flap 74 in which are located a pair of rectangular openings 76. We may choose to utilize small tabs at the end of both the minor flap 64 and the minor flap 74. As in the case of the previously mentioned rectangular openings 46 and 56, the openings 66 and 76 are intended to coincide with like openings provided in the basic pallet member, so as to make possible the entry of the forks of a forklift truck.

[0053] To prevent the basic pallet member 12 from sliding out either end of the encapsulating member 20, we prefer to use a pair of intermediate size, almost square flaps 68 affixed to the minor flap 64, and a pair of intermediate size, almost square flaps 78 affixed to the minor flap 74. Although this is the preferred arrangement, it is possible in accordance with this invention to use a single intermediate size flap in lieu of the pair of flaps 68, and a single intermediate size flap in lieu of the pair of flaps 78. The occasion for the utilization of the intermediate size flaps will shortly become more apparent.

[0054] Turning now to FIG. 3, it will be noted that here we illustrate the manner in which we go about folding the flaps of the encapsulating member 20 around the basic pallet member 12, in order to achieve an encompassing or enclosing procedure serving to create our novel three piece glueless pallet. It will be observed in FIG. 3 that we have already moved the intermediate size flaps 68 onto the upper surface of one end of the basic pallet member 12, and in a like manner, we have also moved the intermediate size flaps 78 onto the upper surface of the other end of the basic pallet member. This having been accomplished, we are ready to start moving the large flaps 24 and 30 onto the upper surface of the basic pallet member. In FIG. 3 we have shown the large flap 30 having been moved to a partial extent insofar as achieving an enclosure of the basic pallet member 12. It will be seen in FIG. 3 that the tabs 32 and 34 are positioned so as to be ready to enter the slots 36 and 38 in the upper surface of the basic pallet member when the large flap 30 has been brought into close contact with the upper surface of the basic pallet member 12.

[0055] Turning to FIG. 4, it will be seen that we have here shown the large flap 24 and the large flap 30 each having been moved into the position in which their respective tabs are ready to enter into a locking relationship with the aforementioned elongate slots 36 and 38 provided in the upper surface of the basic pallet member 12. It will be noted in this figure that the rectangular openings or apertures 76 as well as the rectangular openings or apertures 56 described in conjunction with FIG. 2 are positioned so as to permit entry of the forks of a fork lift truck inasmuch as these openings or apertures line up with rectangular openings or apertures provided in the basic pallet member 12, as were depicted in FIG. 1.

[0056] With reference now to FIG. 5, it will be seen that we have shown the encapsulating member 20 in assembled relationship with the basic pallet member 12, but in this instance a substantial portion of the encapsulating member 20 has been sectioned away so as to reveal the construction permitting the entry of a pair of forks 80 of a forklift truck. It is to be understood that the three-piece pallet 10 is created so as to be a “four-entry pallet,” meaning that the forks of the forklift truck can enter from any of the four sides of the pallet.

[0057] By now it should be abundantly clear that the rectangular openings 76 provided at one end of the encapsulating member line up with the openings 16 provided in the basic pallet member at such time as the basic pallet member has been enclosed; note FIGS. 1 and 3. In a like manner, the rectangular openings 56 provided in one of the long sides of the encapsulating member line up with another set of openings in the basic pallet member, this being openings 18. It is thus readily possible for the forks 80 of the forklift truck to enter a selected pair of openings, as illustrated in FIG. 5.

[0058] The tabs 26 and 28 provided on the large flap 24, and the tabs 32 and 34 provided on the large flap 30 having entered in a locking relationship with the elongate slots 36 and 38 provided in the upper surface of the basic pallet member, the large flaps 24 and 30 lie flat against the upper surface of the basic pallet member, as revealed in FIG. 5. As will thus be apparent, by securing the encapsulating member 20 around the basic pallet member 12 in the abovedescribed manner, we have created a highly effective, lightweight yet sturdy, three-piece pallet requiring no glue or other securing means in its construction.

[0059] With reference now to FIG. 6, it will be seen that we have illustrated an exemplary form of our basic pallet member 12, considered apart from the encapsulating member. The basic pallet member involves a lightweight component foldably constructed from a pair of generally flat, die cut panels 14 and 15, as previously mentioned. Although we are not to be limited to the use of any particular material, our invention is ideally suited for the creation of die cut panels utilizing corrugated paperboard. For example, we may use 350 pound test, double wall corrugated paperboard in the construction of our novel panels, but obviously we are not to be limited to this material. Each of the pair of panels of the basic pallet member 12 is of essentially rectangular configuration, with each panel having ends 146 and 148 as well as sides 152 and 154. It is to be understood that the end 146 is in a parallel relationship with end 148.

[0060] Continuing with a consideration of FIG. 6, it has already been mentioned that the exemplary basic pallet member we have depicted is typically implemented in a size such as 40″ by 40″ or 40″ by 48″. In FIG. 6, the lower panel 15 as well as the upper panel 14 of our novel basic pallet member are constructed from corrugated paperboard that has been folded in a highly effective manner so as to create a plurality of the previously-mentioned longitudinally disposed structural members. In the typical instance, a like number of longitudinally disposed structural members is normally utilized in the creation of each of the panels used in the construction of a given basic pallet member.

[0061] In FIG. 6 it will be noted that four longitudinally disposed structural members, 140, 142, 144 and 150, were formed out of the upper panel 14, and four longitudinally disposed structural members, 160, 170, 180 and 190 were formed out of lower panel 15. There are, however, exceptions to this, such as when, in the design of a special purpose pallet, it may be highly desirable for one end of the pallet to utilize a greater number of the longitudinally disposed structural members than the other end in order that a large, heavy, irregularly-shaped component can be adequately supported.

[0062] It should also be pointed out that by interfitting the longitudinally disposed structural members of one panel in a proper angular relationship with the longitudinally disposed structural members of the other panel, an extremely strong, grid-like construction is created.

[0063] In the particular embodiment depicted in FIG. 6, the previously-mentioned longitudinally disposed structural members 140, 142, 144 and 150 extend between ends 146 and 148 of the panel, whereas the longitudinally disposed structural members 160, 170, 180 and 190 extend between side edges 152 and 154 of the panel.

[0064] It is further to be noted in FIG. 6 that an entry location 167 is defined between longitudinally disposed structural members 160 and 170, and a separate entry location 187 is defined between structural members 180 and 190. It is into the entry location 167 that one fork 80 of a forklift truck may on occasion extend, and into entry location 187 that the other fork 80 may at the same time enter.

[0065] In order to permit the entry of the forks of a forklift truck into the entry locations 167 and 187 in FIG. 6, it was necessary in the formation of the pallet to remove certain mid portions of the longitudinally disposed structural members 140, 142, 144 and 150.

[0066] With reference now to FIG. 7 it will be seen that we have depicted one of the generally flat die cut panels of essentially rectangular configuration as was used in the creation of one of the panels of the basic pallet embodiment illustrated in FIG. 6, with this being the lower panel 15 in this instance.

[0067] In the die cut panel depicted in FIG. 7 it will be seen that the sides 152 and 154 are of greater dimension than the ends 146 and 148. It will be recalled that in many instances, the pallets constructed in accordance with this invention are 40″ in width and 48″ in length, but obviously we are not to be limited to this. It is pertinent to mention that if the panel depicted in FIG. 7 is to be utilized in the creation of a pallet 48″ in length, the distance between the ends 146 and 148 of the die cut panel will be somewhat greater than 48″ inasmuch as when the distance between the ends is caused to decrease during the folding operation utilized to bring about the creation of the plurality of longitudinally disposed structural members, the overall length of the panel will necessarily decrease. In this particular instance, the panel depicted in FIG. 7 is being used to create the lower panel 15 of the pallet illustrated in FIGS. 1 and 6, as was previously mentioned.

[0068] It is to be noted from FIG. 7 that we have shown four groups or sets of scoring lines defined in spaced, parallel locations on the panel, these being groups 160, 170, 180 and 190. From FIG. 6 it was seen that these same numbers apply to the four longitudinally disposed structural members created in conjunction with the lower panel 15.

[0069] It is to be understood that the lower panel illustrated in FIG. 7 in conjunction with a panel of identical or substantially identical construction that has been inverted and turned 90° enables the creation of a basic pallet member of the type depicted in FIGS. 1 and 6. It is for this reason that we find it unnecessary to provide a separate detailed description of both the upper and the lower panel.

[0070] It is to be seen that the scoring lines arranged in the closely spaced parallel groups 160, 170, 180 and 190 of FIG. 7 define positions at which folding can take place when the distance between the ends of each panel is caused to decrease. As will be noted, group 160 is made up of scoring lines 161, 163, 164, 166; group 170 is made up of scoring lines 171, 173, 174, 176; group 180 is made up of scoring lines 181, 183, 184 and 186; and group 190 is made up of scoring lines 191, 193, 194 and 196. Typically the scoring lines are created to reside in a right angle relationship with respect to the direction of the corrugations of the paperboard, but we are not to be limited to this.

[0071] Instead of illustrating FIG. 7 in its initial, flattened condition, it will be noted that we have shown the panel at the time of the commencement of the novel and highly advantageous folding procedure utilized in accordance with this aspect of our invention. This folding procedure serves to create the longitudinally disposed structural members that are quite important in the creation of our novel basic pallet members.

[0072] In FIG. 7 it will be noted with respect to the first group of scoring lines that the central scoring lines 163-164; 173-174; 183-184; and 193-194 have started to move upwardly, out of the plane of the panel. This upward movement of the center portions of the scored groups is caused by the distance between the ends of the panel starting to decrease.

[0073] This upward movement of the scored groups serves to create in each instance, what may be regarded as a first leg between the center scoring line and the scoring line on the left. Similarly, a second leg is created in each group between the center scoring line and the scoring line on the right of each group. By way of example it will be noted in FIG. 7 that the upward movement of the center scoring line 163 serves to create a left leg 162 between this line and the scoring line 161, with the upward movement of the center scoring line 164 serving to create a second or right leg 165 between the center scoring line 164 and the scoring line 166.

[0074] Similarly, the upward movement of the center scoring lines 173 and 174 serves to create a left leg 172 between line 173 and the scoring line 171, and a second or right leg 175 between the second center scoring line 174 and the scoring line 176.

[0075] In addition to the foregoing it will be seen that the upward movement of the center scoring lines 183 and 184 serve to create a left leg 182 between line 183 and the scoring line 181, and a second or right leg 185 between the center scoring line 184 and the scoring line 186.

[0076] Lastly it is to be noted from FIG. 7 that the upward movement of the center scoring lines 193 and 194 serves to create a left leg 192 between line 193 and the scoring line 191, and a second or right leg 195 between the center scoring line 194 and the scoring line 196.

[0077] As an option, we may in some instances prefer to secure the right and left legs of each group together shortly after respective right and left legs have been brought together, with such securing being accomplished such as by the use of an adhesive, or by mechanical fastening means.

[0078] One preferred type of mechanical fastening means will shortly be described in some detail.

[0079] It is thus to be understood that by the time the panel ends 146 and 148 have been moved into their most inward operative relationship, the left and right legs of each group will have been moved into juxtaposition, thus to create the aforementioned longitudinally disposed structural members clearly to be seen in FIG. 6 as structural members 160, 170, 180 and 190. We prefer to identify the upper edges of the longitudinally disposed structural members as crests.

[0080] It is to be noted that the slots 261 through 264; slots 271 through 274; slots 281 through 284; and slots 291 through 294 are provided for the purpose of this panel and a like panel used thereabove to be interfitted. In the preferred instance, the longitudinally disposed structural members of one panel are disposed in an orthogonal relationship with the longitudinally disposed structural members of the other panel, to form a very strong, gridlike member. However, there may be instances in which the longitudinally disposed structural members of one panel meet with the longitudinally disposed structural members of the other panel at an angle other than a right angle.

[0081] With regard to the depth of the slots, the slots provided at spaced locations along the upper portion of the longitudinally disposed structural members of one panel are typically of the same depth as the slots utilized in the longitudinally disposed structural members of the other panel. By having all of the slots of an appropriate depth, when the panels have been interfitted together, the crests of the series of longitudinally disposed structural members of each panel reside in firm contact with the undersurface of the other panel. More particularly, when the upper and lower panels are assembled in the desired angular relationship, the slots created in the longitudinally disposed structural members of the upper panel interfit with the slots created in the longitudinally disposed structural members of the lower panel.

[0082] Slots that are too shallow are undesirable, for when the panels are interfitted, the combined height of the intersecting longitudinally disposed structural members will be too great, and the crests forming the tops of the longitudinally disposed structural members of one panel will not be in contact with the underside of the other panel. On the other hand, if the slots in the longitudinally disposed structural members are too deep, this serves to unnecessarily diminish the strength of the longitudinally disposed structural members.

[0083] Although it is highly desirable for the slots, when intersecting, to be of a depth permitting the crests of the longitudinally disposed structural members of each panel to be in contact with the underside of the other panel, it is possible for the slots of one panel to be of a somewhat different depth than the slots of the other panel, while still permitting the desired contact of the crests of the longitudinally disposed structural members with the underside of the other panel.

[0084] It is important to understand that quite advantageously, we do not need to utilize glue or any other securing means between the two panels in view of our use of the novel encapsulating member 20.

[0085] Turning now to FIG. 8, it will be seen that we have shown an embodiment of our invention involving the preferred type of mechanical means for securing together, the adjacent legs of the longitudinally disposed structural members, instead of utilizing adhesive or another means for this purpose. In FIG. 8 we use an interlocking tab arrangement typically involving one or more interlocking tabs on one leg of a longitudinally disposed structural member, and corresponding tab-receiving slots on the other leg of the structural member. The tab-receiving slots or apertures are to be placed at locations directly opposite each locking tab.

[0086] By referring to FIG. 9, the details of the interlocking tab arrangement we prefer to utilize will become more apparent. For convenience we have designated the legs of a typical longitudinally disposed structural member to be legs L1 and L2.

[0087] As revealed in FIG. 9, we have shown a typical locking tab or locking component to involve a generally “T” shaped component 86 located in leg L1, with it to be understood that the component 86 is to be received in a slot or opening 88 located in the opposite leg, which is L2. Each slot 88 is of course to be placed in careful alignment with each interlocking tab 86.

[0088] The “T” shaped component 86 is constituted by an elongate, straight-sided portion 90, with oppositely placed wing portions 92 and 96 being attached to one end of the straight-sided portion 90.

[0089] It is important to note that a score line 100 is located at the base of the straight-sided portion 90, and a score line 94 is utilized between the portion 90 and the wing 92. Somewhat similarly, a score line 98 is utilized between the portion 90 and the wing 96.

[0090] As will be obvious to those skilled in this art, the score lines make possible a type of hinging action between certain of these components.

[0091] In contrast with the use of score lines, cut lines exist along the left and right sides of the portion 90 as viewed in FIG. 9, and around the outer portions of the wing portions 92 and 96. Also, a cut line exists across the top of the straight-sided portion 90 as viewed in this figure. Because of this arrangement, our “T” shaped locking tab 86 is in effect free of leg L1, except for the hinge existing at the base location 100.

[0092] Upon the legs L1 and L2 of the longitudinally disposed structural members being brought together, the straight-sided portion 90 with its attached wings 92 and 96 can be pushed through the slot 88 located in leg L2. The wings 92 and 96 fold backward during this insertion, but afterward the wings to a large extent return to the plane of the straight-sided portion 90; note FIG. 10 in this regard. The restoration of the wings to positions closely corresponding to their original positions serve in a well understood manner to secure the adjacent legs L1 and L2 together.

[0093] The leg-securing process involving the use of the interlocking tab arrangement can be accomplished mechanically or manually. The mechanical process calls for an arm to be positioned such that as the necessary folds are made to form the upright legs or longitudinally disposed structural members of a panel to be used in the construction of the basic pallet, the arm pushes the locking tabs through the opposing slot of the immediately adjacent leg, thus locking the contiguous legs together. The memory recoil action of the corrugated paperboard makes it unnecessary for any further processes to insure a secure lock. If a manual procedure is to be used, the same basic action takes place, with the lock tabs being pushed through the adjacent slots with a thumb or finger.

[0094] Turning now to FIG. 11, we here depict an encapsulating member generally along the lines of FIG. 2 but at this location showing an embodiment of our invention that contains suitable apertures 136 through 139, such that the completed pallet can be used with a pallet jack.

[0095] FIG. 12 is a perspective view of the basic pallet member generally along the lines of FIG. 6, but here indicating the use of apertures in the lower surface of the basic pallet member that coincide with the apertures in the encapsulating member, such that the completed pallet can be used with a pallet jack. Note fork members 80 of the pallet jack.

[0096] The way we preferably go about converting the prescored die cut panels into panels in which the longitudinally disposed structural members have been created is by the use of the machine set forth in the Olvey et al patent application Ser. No. ______ filed in the U.S. Patent & Trademark Office on ______ and entitled “______.”

[0097] That machine involves the use of a type of table whose planar upper surface is made up of a plurality of flat metal members with some of these members spaced apart so as to define longitudinally placed slots. A previously scored die cut panel that is to be formed into a panel capable of being interfitted with a like panel is caused to move in a precise manner across the surface of the forming table, such as by the use of an array of endless chains operative in the slotted locations defined between the flat metal members forming the upper surface of the table.

Claims

1. A three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels of essentially rectangular configuration, with each of said panels having ends and sides and with said ends residing in an essentially parallel relationship,

a plurality of parallel, longitudinally disposed structural members created on the inner surface of each panel,

during the creation of a basic pallet member by the use of said panels, one of said panels being turned such that its structural members are disposed in an angular relationship to the structural members of the other of said panels,

a plurality of slots formed at spaced locations in the structural members of each basic panel member, with such slots in the structural members of one panel positioned so as to coincide with the location of said structural members of the other panel, so that when the two panels are pushed together in an aligned relationship, the slots of the structural members of one panel enter and interfit with respective slots of the other panel,

said interfitted panels, upon thereafter being placed inside an encapsulating member constructed of lightweight material, forming an integral, three-piece pallet unit of considerable strength.

2. A three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which each of said plurality of parallel, longitudinally disposed structural members is made up of separate, longitudinally extending legs whose inner surfaces have been secured together.

3. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 2 in which said inner surfaces of said longitudinally disposed structural members are secured together by adhesive means.

4. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 2 in which said inner surfaces of said longitudinally disposed structural members are secured together by mechanical means.

5. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 4 in which the mechanical means by which said inner surfaces of said longitudinally disposed structural members are secured together involves the use of interlocking tabs.

6. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which said plurality of slots formed at spaced locations in the structural members of one of said basic panel members are of approximately the same depth as the slots formed in the structural members of the other of said basic panel members.

7. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which said plurality of slots formed at spaced locations in the structural members of one of said basic panel members are of a somewhat different depth than the slots formed in the structural members of the other of said basic panel members.

8. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which at least one of said longitudinally disposed structural members is disposed on one side of a centerline location that is parallel to and substantially equidistant from the ends of each panel, and another of said longitudinally disposed structural members is disposed at a corresponding location on the other side of said centerline location.

9. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which a plurality of longitudinally disposed structural members are disposed on each side of said centerline location.

10. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which at least one of said longitudinally disposed structural members is disposed on one side of a centerline location that is parallel to and substantially equidistant from the ends of each panel, and a plurality of said longitudinally disposed structural members are disposed on the other side of said centerline location.

11. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which during the creation of a basic pallet member by the use of said panels, one of said panels is turned such that its structural members are disposed in an orthogonal relation to the structural members of the other of said panels.

12. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which said encapsulating member involves a central portion equipped with flaps, with two of said flaps being major flaps provided with locking tabs, and at least two tab-receiving slots provided in said basic pallet member for receiving said locking tabs at such time as said basic pallet member has been placed upon said central portion and said major flaps have been folded to enclose said basic pallet member.

13. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 12 in which said tab-receiving slots provided in said basic pallet member for receiving said locking tabs are located on the centerline of said basic pallet member.

14. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 1 in which each of said panels as well as said encapsulating member are made from corrugated paperboard.

15. A three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels of essentially rectangular configuration, with each of said panels having ends and sides and with said ends residing in an essentially parallel relationship,

a plurality of parallel, longitudinally disposed structural members created on the inner surface of each panel,

a first of said longitudinally disposed structural members being disposed on one side of a centerline location parallel to and substantially equidistant from the ends of each panel,

a second of said longitudinally disposed structural members being disposed on the other side of said centerline location,

during the creation of a basic pallet member by the use of said panels, one of said panels being turned such that its structural members are disposed in an orthogonal relation to the structural members of the other of said panels,

a plurality of slots formed at spaced locations in the structural members of each basic panel member, with such slots of one panel positioned so as to coincide with the location of said structural members of the other panel, so that when the two panels are pushed together in an aligned relationship, the slots of the structural members of one panel enter and interfit with respective slots of the other panel,

said interfitted panels, upon thereafter being placed inside an encapsulating member constructed of lightweight material, forming an integral pallet unit of considerable strength.

16. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 in which each of said plurality of parallel, longitudinally disposed structural members are made up of separate, longitudinally extending legs whose inner surfaces have been secured together.

17. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 16 in which said inner surfaces of said longitudinally disposed structural members are secured together by adhesive means.

18. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 16 in which said inner surfaces of said longitudinally disposed structural members are secured together by mechanical means.

19. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 18 in which the mechanical means by which said inner surfaces of said longitudinally disposed structural members are secured together involves the use of interlocking tabs.

20. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 in which said first longitudinally disposed member and said second longitudinally disposed member are disposed on opposite sides of said centerline location at approximately the same distance from said centerline location.

21. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 wherein a plurality of longitudinally disposed structural members are disposed on each side of said centerline location.

22. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 wherein a different number of longitudinally disposed structural members are disposed on one side of said centerline location, than are disposed on the other side of said centerline location.

23. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 in which said encapsulating member involves a central portion equipped with flaps, with two of said flaps being major flaps provided with locking tabs, and at least two tab-receiving slots provided in said basic pallet member for receiving said locking tabs at such time as said basic pallet member has been placed upon said central portion and said major flaps have been folded to enclose said basic pallet member.

24. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 23 in which said tab-receiving slots are disposed on the centerline of said basic pallet member.

25. The three-piece lightweight pallet involving the use of a basic pallet member constructed from a pair of generally flat, die cut panels utilized in combination with an encapsulating member as recited in claim 15 in which each of said panels as well as said encapsulating member are made from corrugated paperboard.

26. A three-piece lightweight pallet involving the use of a basic pallet member utilized in combination with an encapsulating member, said basic pallet member being constructed from a pair of generally flat, die cut panels of essentially rectangular configuration, with each of said panels having ends and sides and with said ends residing in a parallel relationship,

a plurality of scoring lines defined in spaced, parallel locations on each of said panels, with such scoring lines being arranged in closely spaced groups, and with such scoring lines defining positions at which folding can take place when the distance between the ends of each panel is caused to decrease,

a first closely spaced group of such scoring lines being disposed on one side of a centerline location parallel to and substantially equidistant from the ends of each panel, and a second closely spaced group of such scoring lines being disposed at a corresponding location on the other side of said centerline location, with each of said panels being susceptible to a folding procedure taking place at each position at which a closely spaced group of scoring lines are located,

said panels, upon the distance between said ends being caused to decrease so as to bring about folding at the locations of each closely spaced group of scoring lines, forming on one surface of each panel, a plurality of parallel, longitudinally disposed structural members whose inner surfaces are able to be secured together to resist bending,

during the creation of a basic pallet member by the use of said panels, one of said panels being turned such that its structural members are disposed in an angular relation to the structural members of the other of said panels,

a plurality of slots formed at spaced locations in the structural members of each panel, with such slots positioned so as to coincide with the location of said structural members of the other panel, so that when the two panels are pushed together in an aligned relationship, the slots of the structural members of one panel enter and interfit with respective slots of the other panel, with the interfitted panels, upon being joined together, forming a basic pallet member of considerable strength,

said basic pallet member being utilized in combination with an encapsulating member of lightweight material designed to readily receive the basic pallet member.

27. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 26 in which said inner surfaces of said longitudinally disposed structural members are secured together by adhesive means.

28. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 26 in which said inner surfaces of said longitudinally disposed structural members are secured together by mechanical means.

29. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 28 in which said mechanical means by which the inner surfaces of said longitudinally disposed structural members are secured together is by the use of interlocking tabs.

30. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 26 in which said longitudinally disposed structural members of one panel are disposed in an orthogonal relationship to the structure members of the other panel.

31. Three two-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 26 in which said encapsulating member involves a central portion equipped with flaps, with two of said flaps being major flaps provided with locking tabs, and at least two tab-receiving slots provided in said basic pallet member for receiving said locking tabs at such time as said basic pallet member has been placed upon said central portion and said major flaps have been folded to enclose said basic pallet member.

32. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 31 in which said tab-receiving slots are disposed on the centerline of said basic pallet member.

33. The three-piece lightweight pallet involving the use of a basic pallet member utilized in conjunction with an encapsulating member as recited in claim 26 in which each of said panels as well as said encapsulating member are made from corrugated paperboard.

34. The three-piece lightweight pallet involving the use of a basic pallet member utilized in combination with an encapsulating member as recited in claim 26 in which generally rectangularly shaped apertures are provided in said basic pallet member that are intended to receive the forks of a fork lift truck, which apertures substantially align with similar apertures in said encapsulating member at such time as said encapsulating member is installed around said basic pallet member.