PAPERBOARD PALLET
A paperboard pallet is provided that includes first and second cardboard stringers positioned substantially parallel to each other. A space is formed between the first and second stringers. At least a first deck board is attached to and positioned substantially perpendicular to the first and second stringers. Both the first and second stringers include a notch on their top sides. Each notch on the top side of the first and second stringer is sized to receive the first deck board, and is located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers.
This application is a continuation-in-part application to U.S. patent application Ser. No. 14/203,042, filed Mar. 10, 2014, entitled “Paperboard Pallet” and claims the benefit of U.S. Provisional Application Ser. No. 61/897,987 filed Oct. 31, 2013, entitled “Paperboard Pallet—3” and claims the benefit of U.S. Provisional Application Ser. Nos. 61/776,553, filed Mar. 11, 2013, entitled “Paperboard Pallet” and U.S. Provisional Application Ser. No. 61/776,588, filed Mar. 11, 2013, entitled “Machine and Method for Making a Corrugated Paperboard Pallet” which are hereby incorporated by reference in their entirety.
TECHNICAL FIELDThe present disclosure relates to corrugated paper, cardboard, and/or fiber board pallets, as well as a method for making the same.
BACKGROUND AND SUMMARYConventional pallets are typically made of wood or plastic. Wood pallets consist of a plurality of spaced apart wood boards or stringers that are sandwiched between a plurality of spaced apart deck boards. These deck boards generally run parallel to each other and perpendicular to the stringers. When all the deck boards and stringers are nailed together, a secure platform is created that accommodates cargo, product, and other materials. In such wood pallet designs, spaces exist between the upper and lower deck boards that sandwich the stringers. These spaces are sized to accommodate forklift blades so that the products or materials setting on the pallet can all be lifted at one time when the forklift lifts the pallet.
The present disclosure is directed to a pallet made of cardboard or paperboard. Illustratively, the pallet may be made of corrugated cardboard. In one embodiment, a pallet may be made of cardboard stringers and deck boards. The stringers may be made of a composite of corrugated cardboard strips laminated together with glue to create a lightweight rigid structure. Similarly, the deck boards may be made from laminated strips of cardboard. The paperboard pallet provides a lightweight, high strength, solution for packing and/or warehousing product where a strong pallet is necessary but wood cannot be used because of issues such as insects in the pallet wood. For example, the food industry requires much of its packaged food product be stored and shipped on pallets, but insects in wood pallets pose a contamination risk. A paperboard pallet solution serves the pallet need, but does not have the issue with insects that a natural wood has.
Another illustrative embodiment of the present disclosure provides a paperboard pallet. The paperboard pallet comprises first and second stringers positioned substantially parallel to each other. Each of the first and second stringers is made of a plurality of bonded sheets of cardboard. A space is formed between the first and second stringers. Each of the first and second stringers has a top side, an underside, and a first end. The underside is located opposite the top side. At least a first deck board attached to the first and second stringers and positioned substantially perpendicular to the first and second stringers. Both the first and second stringers include a notch on their top sides. Each notch on the top side of the first and second stringer is sized to receive the first deck board. Each notch is also located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers. Both the first and second stringers include a notch on their undersides. A second deck board is provided as well. Each notch on the underside of the first and second stringers is sized to receive the second deck board. These underside notches are also located so a first side of the second deck board is located substantially flush with the first end of the first and second stringers. A paper wrap is attached to the underside and sides of the first and second stringers, the second deck board, and spans the space formed between the first and second stringers.
In the above and additional embodiments, the paperboard pallet may further comprise: the cardboard is corrugated cardboard; a third stringer located in the space formed between the first and second stringers, which creates a second space in addition to the first space, wherein the space and the second space are each sized to receive a forklift fork; both of the first and second stringers have a second end located opposite the first end; a second deck board positioned substantially parallel to and spaced apart from the first deck board; a second notch on the top side of each of the first and second stringers, wherein each second notch on the top side of the first and second stringers is sized to receive the second deck board; the second deck board is fitted in the second notch on the top side of each of the first and second stringers, wherein the deck board is substantially flush with the topside of the first and second stringers; the paper wrap is selected from the group consisting of paper, kraft paper, and cardboard; the paper wrap includes first and second forklift openings that coincide with forklift openings in the first and second stringers.
Additional features and advantages of the paperboard pallet will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrated embodiment exemplifying the best mode of carrying out the paperboard pallet as presently perceived.
The present disclosure will be described hereafter with reference to the attached drawings which are given as non-limiting examples only, in which:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of the paperboard pallet and method of making, and such exemplification is not to be construed as limiting the scope of the paperboard pallet and method of making in any
DETAILED DESCRIPTION OF THE DRAWINGSA perspective view of an illustrative embodiment of a paperboard pallet 2 is shown in
A side view of pallet 2 is shown in
A side exploded view of pallet 2 is shown in
A perspective of another illustrative embodiment of a paperboard pallet 28 is shown in
A side view of pallet 28 is shown in
A side exploded view of pallet 28 is shown in
A perspective view of another illustrative embodiment of a paperboard pallet 50 is shown in
A side view of pallet 50 is shown in
A side view of stringer 52 is shown in
A front view of pallet 50 is shown in
A perspective view of another illustrative embodiment of paperboard panel 70 is shown in
A perspective view of another illustrative embodiment of a paperboard pallet 80 is shown in
A front view of pallet 80 (like pallet 70) demonstrating how wrapped sheet 82 folds around stringers 84, 86, and 88, is shown in
Top views of cardboard sheets 78 and 82 in unfolded configurations are shown in
A perspective view of another illustrative embodiment of a paperboard pallet 100 is shown in
A front view of a partially folded wrapped sheet 82 (or wrapped sheet 78) is shown in
A top view of pallet 100 with deck boards 102 attached on top is shown in
A perspective view of an unassembled stringer 118 is shown in
Another illustrative embodiment of the present disclosure provides a paperboard pallet 200. Paperboard pallet 200 includes parallel-spaced apart stringers 204, 206, and 208. It is appreciated that they are sized as desired based on its use. Deck boards 210 extend transversely to the orientation of the stringers on the top and bottom surfaces. Leading edge deck boards 212 and 214 are similar construction to deck boards 210 except they are located on the top and bottom ends of paperboard pallet 200, respectively. Each deck board fits into a notch 215(see also
A perspective view of an illustrative embodiment of stringers 204, 206 or 208 is shown in
The several perspective views shown in
A top view of an unfolded liner 228 is shown in
A side view of an illustrative flute 230 is shown in
A top view of a paperboard shape wrap 220 is shown in
Although the present disclosure has been described with reference to particular means, materials, and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the present disclosure and various changes and modifications may be made to adapt the various uses and characteristics without departing from the spirit and scope of the present invention as set forth in the following claims.
Claims
1. A paperboard pallet comprising:
- first and second stringers positioned substantially parallel to each other;
- wherein each of the first and second stringers is made of a plurality of bonded sheets of cardboard;
- wherein a space is formed between the first and second stringers;
- wherein each of the first and second stringers has a top side, an underside, and a first end, wherein the underside is located opposite the top side;
- at least a first deck board attached to the first and second stringers and positioned substantially perpendicular to the first and second stringers;
- wherein both the first and second stringers include a notch on their top sides;
- wherein each notch on the top side of the first and second stringer is sized to receive the first deck board, and is located so a first side of the first deck board in each notch in the top side of the first and second stringers is located substantially flush with the first end of the first and second stringers;
- wherein both the first and second stringers include a notch on their undersides;
- a second deck board;
- wherein each notch on the underside of the first and second stringers is sized to receive the second deck board, and is located so a first side of the second deck board in each notch of the underside of the first and second stringers is located substantially flush with the first end of the first and second stringers; and
- a paper wrap is attached to the underside and sides of the first and second stringers and the second deck board, and spans the space formed between the first and second stringers.
2. The paperboard pallet of claim 1, wherein the cardboard is corrugated cardboard.
3. The paperboard pallet of claim 1, further comprising a third stringer located in the space formed between the first and second stringers, which creates a second space in addition to the first space, wherein the space and the second space are each sized to receive a forklift fork.
4. The paperboard pallet of claim 1, wherein both the first and second stringers have a second end located opposite the first end.
5. The paperboard pallet of claim 1, further comprising a second deck board, wherein the second deck board is positioned substantially parallel to and spaced apart from the first deck board.
6. The paperboard pallet of claim 5, further comprising a second notch on the top side of each of the first and second stringers, wherein each second notch on the top side of the first and second stringers is sized to receive the second deck board.
7. The paperboard pallet of claim 6, wherein the second deck board is fitted in the second notch on the top side of each of the first and second stringers, wherein the deck board is substantially flush with the topside of the first and second stringers.
8. The paperboard pallet of claim 1, wherein the paper wrap is selected from the group consisting of paper, kraft paper, and cardboard.
9. The paperboard pallet of claim 1, wherein the paper wrap includes first and second forklift openings that coincide with forklift openings in the first and second stringers.
Type: Application
Filed: Oct 30, 2014
Publication Date: May 7, 2015
Inventors: James A. Frautschi (Lakeville, MN), Ronald L. Leino (Eden Prairie, MN), Randy J. Lehner (Brooklyn Park, MN), Theodore G. Young (Buffalo, MN)
Application Number: 14/528,036
International Classification: B65D 19/00 (20060101);