Pallet and Methods for Making Same

Abstract

A pallet includes a platform having a first side for carrying an object thereon and a second side opposite the first side, and a first elongate rectangular leg member positioned on the second side of the platform proximate a first end of the platform, and a second elongate rectangular leg member positioned on the second side of the platform proximate a second end of the platform opposite the first end. The platform and the leg members can be integrally formed from a single sheet of material, such as corrugated paper. The legs can include openings for receiving support members, such as paper cones or paper tubes.

Description

This application claims priority to U.S. Provisional Application No. 60/747,626, filed May 18, 2006.

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The 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.

A number of 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 INVENTION

It 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 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 is a method for making a pallet that includes the steps of providing a blank sheet of material having a first plurality of fold lines proximate a first end of the blank and a second plurality of fold lines proximate a second end opposite the first end of the blank, and folding the blank along the first plurality of fold lines to form a first leg member proximate the first end of the blank, and along the second plurality of fold lines to form a second leg member proximate the second end of the blank, such that a remaining portion of the blank defines a platform supported by the first and second leg members.

According to another preferred embodiment of the invention, the blank sheet of material is paper.

According to another preferred embodiment of the invention, the first and second pluralities of fold lines include substantially parallel first, second, third and fourth fold lines, and each of the first and second leg members include an elongate rectangular member for supporting the platform above a surface.

According to another preferred embodiment of the invention, an area intermediate the first end of the blank and the first fold line of the first plurality of fold lines is adhered to an area of the blank intermediate the fourth fold line of the first plurality of fold lines and the first fold line of the second plurality of fold lines.

According to another preferred embodiment of the invention, first opening is formed intermediate the first end of the blank and the first fold line of the first plurality of fold lines, and a second opening is formed intermediate the second and third fold lines of the first plurality of fold lines and positioned such that the first and second openings are axially aligned when the blank is folded along first, second, third and fourth fold lines of the first plurality of fold lines.

According to another preferred embodiment of the invention, a support member is positioned within the aligned first and second openings for strengthening the first leg member.

According to another preferred embodiment of the invention, the support member is a paper cone or a paper tube.

According to another preferred embodiment of the invention, a first opening is formed intermediate the first and second fold lines of the first plurality of fold lines of the blank, and a second opening is formed intermediate the third and fourth fold lines of the first plurality of fold lines of the blank. A third opening is formed intermediate the first and second fold lines of the second plurality of fold lines of the blank, and a fourth opening is formed intermediate the third and fourth fold lines of the second fold lines of the blank. The first, second, third and fourth openings are axially aligned when the blank is folded along the first and second pluralities of fold lines such that the first and second leg members define an area for receiving at least one fork of a forklift.

According to another preferred embodiment of the invention, perforated sections are formed proximate the first, second, third and fourth openings of the blank such that the perforated sections are separable from the blank to enlarge the first, second, third and fourth openings.

According to another preferred embodiment of the invention, a third leg member is attached on the platform intermediate the first and second leg members.

According to another preferred embodiment of the invention, the first and second pluralities of fold lines each include substantially parallel first, second, third, fourth, fifth and sixth fold lines, and each of the first and second leg members include an elongate rectangular member for supporting the platform above a surface. The platform includes a first wing section extending outwardly from the first leg member and a second wing section extending outwardly from the second leg member.

According to another preferred embodiment of the invention, the first and second leg members are mounted on a substantially flat base member. The base member can include at least one opening for receiving a pallet jack.

According to yet another preferred embodiment of the invention, a pallet includes a platform having a first side for carrying an object thereon and a second side opposite the first side, and a first elongate rectangular leg member positioned on the second side of the platform proximate a first end of the platform, and a second elongate rectangular leg member positioned on the second side of the platform proximate a second end of the platform opposite the first end.

According to another preferred embodiment of the invention, the platform and the first and second leg members are integrally formed from a single sheet of paper.

According to another preferred embodiment of the invention, the first leg member includes at least four walls formed by making at least four folds proximate a first end of the sheet of paper, and the second leg member includes at least four walls formed by making at least four folds proximate a second end of the sheet of paper opposite the first end.

According to another preferred embodiment of the invention, the first leg member is coextensive with the first end of the platform, and the second leg member is coextensive with the second end of the platform.

According to another preferred embodiment of the invention, a third elongate rectangular leg member is mounted on the second side of the platform at a position intermediate the first and second leg members, and the first, second and third leg members are substantially parallel.

According to another preferred embodiment of the invention, a substantially flat base member is attached to the first and second leg members for positioning on a surface, and the base member includes at least one opening for inserting a pallet jack therethrough.

According to another preferred embodiment of the invention, the pallet is made of corrugated paper. The platform and the first and second leg members can be corrugated in one direction, while the base member is corrugated in the opposite direction.

According to another preferred embodiment of the invention, a plurality of support members, such as a paper tubes and/or cones, are positioned in the first and second leg members in substantially perpendicular relation to the platform.

According to another preferred embodiment of the invention, the first leg member includes a first opening, and the second leg member includes a second opening aligned with the first opening on an axis substantially parallel with the platform such that at least one fork of a fork lift can be inserted within the first and second openings.

According to another preferred embodiment of the invention, each of the first and second leg members includes a first wall attached and parallel to the platform, a second wall extending perpendicularly from the first wall, a third wall extending perpendicularly from the second wall and parallel to the platform for supporting the platform on a surface, and a fourth wall extending perpendicularly from the third wall and connecting the third wall to the platform.

According to another preferred embodiment of the invention, the second and fourth walls of the first and second leg members each include a flap section that is at least partially removable to define an opening for receiving at least one fork of a fork lift.

According to another preferred embodiment of the invention, the platform includes a first wing section extending outwardly from the first leg member, and a second wing section extending outwardly from the second leg member.

BRIEF DESCRIPTION OF THE DRAWINGS

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;

FIG. 1 is a perspective view of a pallet according to a preferred embodiment of the invention,

FIG. 2 is another perspective view of the pallet of FIG. 1;

FIG. 3 is yet another perspective view of the pallet of FIG. 1;

FIG. 4 is yet another perspective view of the pallet of FIG. 1;

FIG. 5 is partial perspective view of the pallet of FIG. 1;

FIG. 6 is a partial cross sectional view of the pallet of FIG. 1;

FIG. 7 is a partial perspective view of the pallet of FIG. 1;

FIG. 8 is another partial perspective view of the pallet of FIG. 1;

FIG. 9 is yet another partial perspective view of the pallet of FIG. 1;

FIG. 10 is a partial cross sectional view of the pallet of FIG. 1;

FIG. 11 is a partial cross sectional view of a pallet according to another preferred embodiment of the invention;

FIG. 11A is a partial cross sectional view of the pallet of FIG. 11, shown in use with a second similar pallet;

FIG. 12 is another partial cross sectional view of the pallet of FIG. 11;

FIG. 13 is a perspective view of a pallet according to another preferred embodiment of the invention;

FIG. 14 is another perspective view of the pallet of FIG. 13;

FIG. 15 is a partial cross sectional view of the pallet of FIG. 14, taken along lines 15-15;

FIG. 16 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 17 is a top plan view of a die cut sheet for use in a preferred method of making the pallet of FIG. 13;

FIGS. 18-21 are partial perspective views illustrating a preferred method of making the pallet of FIG. 13;

FIG. 22 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 23 is another perspective view of the pallet of FIG. 22;

FIG. 24 is a partial cross sectional view of the pallet of FIG. 23, taken along lines 24-24;

FIG. 25 is a perspective view of a pallet according to yet another preferred embodiment of the invention;

FIG. 26 is a top plan view of a die cut sheet for use in a preferred method of making the pallet of FIG. 23;

FIGS. 27-31 are partial perspective views illustrating a preferred method of making the pallet of FIG. 23;

FIG. 32 is a perspective view of a pallet according to yet another preferred embodiment of the invention; and

FIG. 33 is a perspective view of a pallet according to yet another preferred embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS AND BEST MODE

A pallet according to a preferred embodiment of the invention is illustrated in FIGS. 1-4, and shown generally at reference numeral 10. The pallet 10 includes a platform 12 with a plurality of circular openings 14 and a leg 22 positioned within each of the openings 14. The legs 22 are preferably conical and positioned such that the larger diameter end 24 of each leg 22 is connected to the platform 12, and the smaller diameter end 26 rests on the floor.

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 FIGS. 3 and 4, the legs 22 are conical and open at both ends 24, 26, and are tapered at an angle of about 10 degrees. The legs 22 are made of 3-3.5 laps of 380-400 g/sqm paper having a thickness of 630 microns, and have a length of 116 mm. The inner diameter of the large diameter end 24 is 100 mm, and the inner diameter of the small diameter end 26 is 59 mm. The large diameter end 24 has a radius pattern 294, and the small diameter end 26 has a radius pattern of 177. Each leg 22 preferably weighs 40.7 grams. The pallet 10 is thus conducive to recycling and disposal as it can be made completely of paper.

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 FIG. 5, the platform 12 includes foldable flap sections 16 proximate the openings 14. The openings 14 are sized such that the flap sections 16 fold downwardly and engage the large diameter end 24 of the legs 22 when the legs 22 are pushed through the openings 14. The adhesive on the legs 22 adheres to the flap sections 16 of the platform 12. Alternatively, the adhesive can be put on the flap sections 16 prior to positioning the legs 22 within the openings 14.

As shown in FIGS. 6 and 7, each leg 22 has a bull nose 28 formed at the small diameter end 26. The bull nose 28 is formed by folding a portion of the leg 22 inwardly so that the bull nose 28 extends around the circumference of the inner wall surface of the leg 22.

As shown in FIGS. 8-10, the pallet 10 can be nested within another like pallet 10′, and vice versa. As shown in FIGS. 9 and 10, the bull nose 28 of the first pallet 10 provides a stop for the leg 22′ of a second pallet 10′ that is being nested within the first pallet 10. As such, the second pallet 10′ is prevented from sliding all the way to the end of the leg 22 of the first pallet 10, thereby preventing the two pallets 10, 10′ from getting stuck too tightly together while in storage. This facilitates separation of the two pallets 10, 10′ when it is desired to next use the pallets 10, 10′ for material transport. Additional pallets can be nested, such as is illustrated in FIG. 8, which shows the nesting of four pallets 10.

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 FIGS. 11-12, and shown generally at reference numeral 100. The pallet 100 is similar in construction to the previously described pallet 10, except that each leg 122 of the pallet 100 has two cones 122a, 122b. This construction adds strength to the legs 122 and enables the pallet 100 to withstand heavier loads.

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 FIG. 11, the outer cone 122a is sloped at an angle α relative to the vertical axis that is greater than the sloped angle β of the inner cone 122b. Preferably, the angle α of the outer cone 122a is about ten degrees, and the angle β of the inner cone 122b is about eight degrees. This results in an area between the flared portions 123a, 123b of the outer cone 122a and inner cone 122b, respectively, within which a portion 114 of the platform 112 can be sandwiched.

As shown in FIG. 11A, the leg 122′ of a second pallet 100′ can be nested within the leg 122 of the pallet 100, and since the outer cone 122a′ of leg 122′ of the nesting pallet 100′ has a slightly greater angle α than the angle β of the inner cone 122b of the receiving pallet 100, the nesting pallet 100′ is not allowed to descend all the way to the very bottom of the leg 122 of the receiving pallet 100. This prevents the two pallets 100, 100′ from becoming stuck to tightly together and facilitates easy separation of the two pallets 100, 100′.

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 FIGS. 13 and 14, and shown generally at reference numeral 200. The pallet 200 includes a platform 212 and three leg members 201, 202, 203.

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 FIGS. 13 and 14, it can be a variety of suitable shapes. Three leg members 201, 202, 203 are positioned on the under side 214 of the platform in substantially parallel relation to each other. The first leg member 201 is positioned at one end 215 of the platform 212, and the second leg member 202 is positioned at the opposite end 216 of the platform 212. The third leg member 203 is positioned intermediate the first and second leg members 201, 202 at approximately the center of the platform 212. The leg members 201, 202, 203 are substantially parallel with each other.

As shown in FIG. 13, each of the three leg members 201, 202, 203 are rectangular, and extend across the width of the platform 212. As such, the first and second leg members 201, 202 are coextensive with the first and second ends 215, 216, respectively, of the platform 212.

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 FIG. 15. The tubes 207 provide added strength and stability to the leg members 201, 202, 203 to enable the pallet 200 to carry heavier loads.

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 FIG. 16. The base member 230 can be positioned on a ground surface.

A preferred method of making the pallet 200 is illustrated in FIGS. 17-21. A blank sheet of material, such as a paper die cut sheet 222, is provided as shown in FIG. 17. Four fold lines 251, 252, 253, 254 are formed at one end 215 of the sheet 222, and four fold lines 261, 262, 263, 264 are formed at the opposite end 216 of the sheet. Perforated sections 225 are positioned between the first and second fold lines 251, 261, 252, 262, and between the third fold lines 253, 263 and fourth fold lines 254, 264 of the sheet 222. A first plurality of linearly aligned circular openings 206a are formed between the first and second ends 215, 216 of the sheet 222 and the first fold lines 251, 261, respectively, of the sheet 222. A second plurality of linearly aligned circular openings 206b are formed between the second fold lines 252, 262 and the third fold lines 253, 263 of the sheet 222.

As shown in FIG. 18, the bottom of the support tubes 207 are positioned within circular openings 206b on the sheet 222. The first end of the 215 of the sheet 222 is folded over at ninety degree angles at the first and second fold lines 251, 252 such that the top of the support tubes 207 are positioned within the circular openings 206a, as shown in FIG. 19. The support tubes 207 have a diameter slightly less than the diameter of the openings 206a, 206b such that the tubes 207 are held in place within the openings 206a, 206b by frictional engagement. The sheet 222 is folded at ninety degree angles at the third and fourth fold lines 253, 254 to form the rectangular leg member 201 having four walls 201a-d, shown in FIG. 21. An adhesive can be applied to the sheet 222 to attach wall 201a thereto. Alternatively, other suitable attachment means can be employed to hold the leg member 201, such as staples, nails or other fasteners. The second leg member 202 is made in the same manner as the first leg member 201, and therefore the process is not described again here.

As shown in FIG. 17, the sheet 222 has two pairs of notches 226 formed at opposite ends of the sheet 222 between the third fold lines 253, 263 and the fourth fold lines 254, 264. When the sides 215, 216 of the sheet 222 are folded to form the leg members 201, 202 as described above, the notches 226 are positioned at the four corners of the pallet 200 on the fourth walls 201d, 202d of the leg members 201, 202, respectively, as shown in FIG. 13. These notches 226 provide an area for receiving and holding a wrapping material, such as polyvinylidene chloride or other plastic wrap, that is to be wrapped around the pallet 200 and the objects being carried on the pallet 200.

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 FIG. 17, the sheet 222 has two notches 228 located at opposite sides of the center of the sheet 222. The third leg member 203 likewise has notches 208 at opposite ends formed in the center of the first and fifth walls 203a, 203e. As such, proper positioning of the third leg member 203 on the sheet 222 is readily obtained by aligning the notches 208 of the leg member 203 with the notches 228 of the sheet 222, as shown in FIGS. 13 and 14. The third leg member 203 can be held in place on the sheet 222 by an adhesive placed on the first wall 203a of the leg member 203 or the sheet 222. Alternatively, other attachment means can be employed such as staples, nails or other fasteners.

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 FIG. 13. The flap sections can be held within the leg members 201, 202 by frictional engagement with the first walls 201a, 202a and third walls 201c, 202c of the leg members 201, 202, respectively.

A pallet according to yet another preferred embodiment of the invention is illustrated in FIGS. 22 and 23, and shown generally at reference numeral 300. The pallet 300 includes a platform 312 and three leg members 301, 302, 303.

The platform 312 has a top side 313, shown in FIG. 23, for carrying objects thereon, and an under side 314, shown in FIG. 22, opposite the top side 313. While the platform 312 is preferably rectangular, it can be a variety of suitable shapes. Three leg members 301, 302, 303 are positioned on the under side 314 of the platform in substantially parallel relation to each other. The first leg member 301 is positioned proximate one end 315 of the platform 312, and the second leg member 302 is positioned proximate the opposite end 316 of the platform 312. The third leg member 303 is positioned intermediate the first and second leg members 301, 302 at approximately the center of the platform 312. The leg members 301, 302, 303 are substantially parallel with each other.

Each of the three leg members 301, 302, 303 are rectangular, and extend across the width of the platform 312, as shown in FIG. 22. The first and second leg members 301, 302 each have four walls 301a-d, 302a-d, respectively. The third leg member 303 has a total of five walls 303a-e. While the leg members 301, 302, 303 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 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 FIG. 22. The fifth wall 303e of the third leg member 303 extends perpendicularly from the fourth wall 303d and lies parallel to and flat on the first wall 303a.

The platform 312 includes wing sections 315a, 316a at opposite ends 315, 316, respectively, as shown in FIGS. 22 and 23. As shown in FIG. 22, the wing sections 315a, 316a extend outward perpendicularly from the fourth walls 301d, 302d of the first and second leg members 301, 302, respectively.

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 301, 302, 303 such that the tubes 307 reside in perpendicular relation to the platform 312, as shown in FIG. 24. The tubes 307 provide added strength and stability to the leg members 301, 302, 303 to enable the pallet 300 to carry heavier loads.

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 FIG. 25. The base member 330 can be attached to the leg members 301, 302, 303 using an adhesive or other attachment means, such as staples, nails or other fasteners. The base member 330 can be positioned on a ground surface, and can include openings 336, which are shaped and sized to receive a pallet jack.

A preferred method of making the pallet 300 is illustrated in FIGS. 26-31. A blank sheet of material, such as a paper die cut sheet 322, is provided as shown in FIG. 26. Six fold lines 351, 352, 353, 354, 355, 356 are formed at one end 315 of the sheet 322, and six fold lines 361, 362, 363, 364, 365, 366 are formed at the opposite end 316 of the sheet 322. A first plurality of linearly aligned circular openings 306a are formed between the first and second ends 315, 316 of the sheet 322 and the first fold lines 351, 361, respectively, of the sheet 322. A second plurality of linearly aligned circular openings 306b are formed between the second fold lines 352, 362 and the third fold lines 353, 363 of the sheet 322.

As shown in FIG. 27, the bottom of the support tubes 307 are positioned within circular openings 306b on the sheet 322. The first end 315 of the sheet 322 is folded over at ninety degree angles at the first and second fold lines 351, 352 such that the top of the support tubes 307 are positioned within the circular openings 306a, as shown in FIG. 28. The support tubes 307 have a diameter slightly less than the diameter of the openings 306a, 306b such that the tubes 307 are held in place within the openings 306a, 306b by frictional engagement. As shown in FIG. 30, the sheet 322 is folded at ninety degree angles at the third and fourth fold lines 353, 354 to form the rectangular leg member 301 having four walls 301a-d, shown in FIG. 31. The sheet is folded at ninety degree angles at the fifth and sixth fold lines 355, 356 to form a side edge 318 that joins the top side 313 and under side 314 of the platform 322.

As shown in FIG. 26, the distance between the end 315 of the platform 322 and the first fold line 351 is greater than the distance between the first and second fold lines 351, 352, second and third fold lines 352, 353, and third and fourth fold lines 353, 354. The relatively greater distance between the end 315 of the platform 322 and the first fold line 351 result in the formation of the wing section 315a extending outward from the leg member 301.

An adhesive can be applied to the sheet 322 to attach wall 301a thereto, as shown in FIG. 29. Alternatively, other suitable attachment means can be employed to hold the leg member 301 to the platform 322, such as staples, nails or other fasteners. The second leg member 302 is made in the same manner as the first leg member 301, and therefore the process is not described again here.

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 FIG. 32, and shown generally at reference numeral 400. The pallet 400 includes a platform 412 and two leg members 401, 402, and is similar to the previously described pallet 200, but does not have a third leg member between the first and second leg members 401, 402. One advantage of pallet 400 is that it can be made entirely of a single sheet of paper or other suitable material.

A pallet according to yet another embodiment of the invention is illustrated in FIG. 33, and shown generally at reference numeral 500. The pallet 500 includes a platform 512, and two elongate rectangular leg members 501, 502. A plurality of conical leg members 522 are positioned between the two elongate rectangular leg members 501, 502, and are arranged in a line that is parallel with the rectangular leg members 501, 502. Although leg members 522 are conical, the leg members 522 can be other shapes such as tubular or square.

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 method for making a pallet comprising the steps of:

(a) providing a blank sheet of material having a first plurality of fold lines proximate a first end of the blank and a second plurality of fold lines proximate a second end opposite the first end of the blank; and

(b) folding the blank along the first plurality of fold lines to form a first leg member proximate the first end of the blank, and along the second plurality of fold lines to form a second leg member proximate the second end of the blank, whereby a remaining portion of the blank defines a platform supported by the first and second leg members.

2. A method according to claim 1, wherein the blank sheet of material comprises paper.

3. A method according to claim 1, wherein each of the first and second pluralities of fold lines comprise substantially parallel first, second, third and fourth fold lines, and each of the first and second leg members comprise an elongate rectangular member for supporting the platform above a surface.

4. A method according to claim 3, further comprising the step of adhering an area intermediate the first end of the blank and the first fold line of the first plurality of fold lines to an area of the blank intermediate the fourth fold line of the first plurality of fold lines and the first fold line of the second plurality of fold lines.

5. A method according to claim 3, further comprising the steps of:

(a) forming a first opening intermediate the first end of the blank and the first fold line of the first plurality of fold lines; and

(b) forming a second opening intermediate the second and third fold lines of the first plurality of fold lines and positioned whereby the first and second openings are axially aligned when the blank is folded along first, second, third and fourth fold lines of the first plurality of fold lines.

6. A method according to claim 5, further comprising the step of positioning a support member within the aligned first and second openings for strengthening the first leg member.

7. A method according to claim 6, wherein the support member comprises at least one selected from the group consisting of a paper cone and a paper tube.

8. A method according to claim 3, further comprising the steps of:

(a) forming a first opening intermediate the first and second fold lines of the first plurality of fold lines of the blank,

(b) forming a second opening intermediate the third and fourth fold lines of the first plurality of fold lines of the blank;

(c) forming a third opening intermediate the first and second fold lines of the second plurality of fold lines of the blank;

(d) forming a fourth opening intermediate the third and fourth fold lines of the second fold lines of the blank; and

(e) wherein the first, second, third and fourth openings are axially aligned when the blank is folded along the first and second pluralities of fold lines whereby the first and second leg members define an area for receiving at least one fork of a forklift.

9. A method according to claim 8, further comprising the step of forming perforated sections proximate the first, second, third and fourth openings of the blank whereby the perforated sections are separable from the blank to enlarge the first, second, third and fourth openings.

10. A method according to claim 1, further comprising the step of attaching a third leg member positioned on the platform intermediate the first and second leg members.

11. A method according to claim 1, wherein the first and second pluralities of fold lines each comprise substantially parallel first, second, third, fourth, fifth and sixth fold lines, and each of the first and second leg members comprise an elongate rectangular member for supporting the platform above a surface, and further wherein the platform includes a first wing section extending outwardly from the first leg member and a second wing section extending outwardly from the second leg member.

12. A method according to claim 1, further comprising the step of mounting the first and second leg members on a substantially flat base member for positioning on a surface, and wherein the base member includes at least one opening for receiving a pallet jack.

13. A pallet made according to the method of claim 1.

14. A pallet comprising:

(a) a platform having a first side for carrying an object thereon and a second side opposite the first side; and

(b) a first elongate rectangular leg member positioned on the second side of the platform proximate a first end of the platform, and a second elongate rectangular leg member positioned on the second side of the platform proximate a second end of the platform opposite the first end.

15. A pallet according to claim 14, wherein the platform and the first and second leg members are integrally formed from a single sheet of paper.

16. A pallet according to claim 15, wherein the first leg member comprises at least four walls formed by making at least four folds proximate a first end of the sheet of paper, and the second leg member comprises at least four walls formed by making at least four folds proximate a second end of the sheet of paper opposite the first end.

17. A pallet according to claim 14, wherein the first leg member is coextensive with the first end of the platform, and the second leg member is coextensive with the second end of the platform.

18. A pallet according to claim 14, further comprising a third elongate rectangular leg member mounted on the second side of the platform at a position intermediate the first and second leg members, wherein the first, second and third leg members are substantially parallel.

19. A pallet according to claim 14, further comprising a substantially flat base member attached to the first and second leg members for positioning on a surface, and wherein the base member includes at least one opening for inserting a pallet jack therethrough.

20. A pallet according to claim 14, wherein the pallet is comprised of corrugated paper, and further wherein the platform and the first and second leg members are corrugated in a first direction, and the base member is corrugated in a second direction opposite the first direction.

21. A pallet according to claim 14, further comprising a plurality of support members positioned in the first and second leg members in substantially perpendicular relation to the platform.

22. A pallet according to claim 14, wherein the first leg member includes a first opening, and the second leg member includes a second opening aligned with the first opening on an axis substantially parallel with the platform whereby at least one fork of a fork lift can be positioned within the first and second openings.

23. A pallet according to claim 14, wherein each of the first and second leg members includes:

(a) a first wall attached and parallel to the platform;

(b) a second wall extending perpendicularly from the first wall;

(c) a third wall extending perpendicularly from the second wall and parallel to the platform for supporting the platform on a surface; and

(d) a fourth wall extending perpendicularly from the third wall and connecting the third wall to the platform.

24. A pallet according to claim 23, wherein the second and fourth walls of the first and second leg members each include a flap section that is at least partially removable to define an opening for receiving at least one fork of a fork lift.

25. A pallet according to claim 14, wherein the platform includes a first wing section extending outwardly from the first leg member, and a second wing section extending outwardly from the second leg member.