CORRUGATED PALLET CONSTRUCTED OF FOLDED, INTERLOCKED BLANKS AND METHOD
An interlock for the top and bottom members of a foldably-constructed pallet and a method of assembling a pallet wherein the top and bottom members are interlocked. By folding straps around the corners of the pallet, either from one sidewall of the pallet around the corner to the adjacent sidewall or from the top of the pallet to the bottom (and optionally from the bottom of the pallet to the top), and anchoring the end of the strap to the adjacent sidewall or the bottom member of the pallet (and if a second strap folded from the bottom member to the top member is utilized, to the top member), the load-bearing capacity of the pallet is substantially increased.
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This application claims the benefit of U.S. Provisional Application Nos. 61/664,827, filed Jun. 27, 2012, and 61/665,358, filed Jun. 28, 2012, which related applications are hereby incorporated in their entirety into this application by this specific reference thereto. This application is also a continuation-in-part of co-pending application Ser. No. 13/134,092, filed May 27, 2011, and a continuation-in-part of co-pending application Ser. No. 13/134,508, filed Jun. 9, 2012, and both prior co-pending applications are also hereby incorporated into this application in their entirety by this specific reference thereto.
The present invention relates generally to a force-resisting structure or support and, more particularly, to a force-resisting structure or support foldably constructed from one or more foldable blanks and especially suited for use as a pallet or dunnage support. In more detail, this invention pertains to pallets for shipping goods, and more particularly to a corrugated paperboard pallet that provides strong and stiff load support utilizing fully recyclable corrugated, and a method of assembling a corrugated paperboard pallet for use in shipping goods that reduces direct and indirect shipping costs. The pallet of the present invention reduces costs by utilizing only two flat paperboard blanks and by requiring the minimum amount of material while being completely machine-assembleable on-site at a shipping facility for rapid, high volume use. The assembly method of the present invention reduces waster material and facilitates just-in-time palletizing with minimal labor, storage, transport, and uncertainty costs.
A pallet is primarily used to accommodate the mechanized bulk handling and transport of products. A pallet typically comprises a flat top surface for supporting a load, such as goods, containers, or packages, a sufficient distance above the ground or floor so that the fork of a forklift can be inserted under the top surface in order to move the pallet with the entire load thereon from place to place. Traditionally, most pallets have been made from pieces of wood, specifically soft wood, assembled with metal fasteners such as nails or screws. However, a number of problems face present day users of conventional wooden pallets. The rising cost of making and repairing wooden pallets has detracted from the overall cost effectiveness of palletized shipments. Wooden pallets are heavy, bulky and cumbersome, and empty wooden pallets require substantial storage space. It is especially costly to transport empty wooden pallets by rail or truck for reuse.
To save costs, conventional wooden pallets are returned to the shipper for reuse, but since wooden pallets are heavy, bulky and cumbersome, they are inconvenient to store and relatively expensive to return to the shipper. If the wooden pallet is not reused, it must be disposed of in a proper manner. Generally speaking, landfill or other waste disposal sites will not accept wooden pallets as is; rather, the pallets must first be reduced either by chipping or burning prior to disposal. Chipping adds significant cost to wooden pallet disposal, and burning wooden pallets is often precluded by environmental regulations.
Some used wooden pallets are retrieved by pallet recyclers, who usually accept only certain sizes of wooden pallets and commonly charge a fee for their retrieval. After repair or refurbishment, the recycler may attempt to resell the used wooden pallets. The market for recycled wooden pallets is limited, however, because many retailers refuse to receive goods transported on recycled wooden pallets due to the lack of any standards regulating the quality of the repair or refurbishment of used wooden pallets. Products shipped internationally on even new wooden pallets are faced with increasing regulations requiring various forms of chemical treatment to the wood to prevent infestation and transport of insects and parasites. Pallets constructed of plastic or metal have been proposed, but plastic and metal pallets have many of the same disadvantages as wooden pallets including being heavy, bulky and cumbersome, being costly and inconvenient to transport, store and dispose of, and being incompatible with environmental preservation. In view of the various drawbacks to pallets made from wood, plastic or metal, it would be desirable to construct a pallet from a material other than wood, plastic or metal, while maintaining many of the desirable characteristics generally associated with pallets made from wood, plastic and metal to provide a pallet that is lighter in weight, less expensive, strong, of simplified construction, easier and less costly to transport and store, that requires less space for storage, that is more readily recyclable or disposable, and that minimizes environmental impact.
Pallets made of corrugated paperboard have been proposed, including pallets constructed from foldable corrugated paperboard blanks as represented by U.S. Pat. No. 6,029,582 to Ogilvie, Jr. et al. In many conventional corrugated paperboard pallets, the vertical supports for the elevated top surface of the pallet are secured with extraneous fasteners, including adhesive fasteners such as glue or mechanical fasteners such as staples or clips, and are not secured by the paperboard blanks themselves. Since an individual pallet ordinarily includes a plurality of vertical supports, the need to apply an extraneous fastener to each vertical support adds to the cost, time, labor and complexity involved in constructing or assembling the pallet. Furthermore, paperboard pallets in which the vertical supports are secured with extraneous fasteners are usually lacking in torsional strength. The extraneous fasteners also introduce undesirable materials into the pallet, and the fasteners may limit or complicate recyclability of the pallet. Some paperboard pallets rely on frictional securement of a top member of the pallet, which defines the elevated top surface, to a bottom member of the pallet, and such frictional securements lend little or no torsional support or strength to the overall pallet structure. Many conventional paperboard pallets do not have full perimeter support for the elevated top surface. Consequently, the force from a load carried on the elevated top surface can cause the elevated top surface to deflect in areas where the load is not directly supported by vertical supports of the pallet. Some conventional paperboard pallets cannot be foldably constructed or assembled from a single paperboard blank but, rather, require at least two foldable paperboard blanks that are assembled and then fastened together with extraneous fasteners. Some paperboard pallets attempt to duplicate the design of conventional wooden pallets, and these pallets are usually both heavy and expensive despite being made of paperboard.
For the many reasons of reducing costs, increasing recyclability, lowering pallet weight, eliminating product contamination, and reducing injuries, there is a desire to replace conventional wooden pallets with corrugated pallets. There is also a desire to have corrugated pallets that can be shipped flat and then be completely machine- assembled on-site at a product shipper to facilitate high volume, just-in-time supply and to reduce pallet storage space and costs. To date, corrugated pallets have required some or total hand assembly, making high volume use difficult, have used excessive amounts of corrugated paperboard, making them expensive, and have had less than sufficient strength and stiffness for shipping many loads. Accordingly, an improved corrugated pallet is needed that provides increased strength and stiffness for widespread use in shipping, that makes minimal use of corrugated for lower costs, and that can be completely machine-assembled for rapid, high-volume product shipping applications.
Various objects, features and advantages of the present invention will become apparent from the following description of the preferred embodiments taken in conjunction with the accompanying drawings wherein like reference numerals refer to like or similar parts. Those skilled in the art will recognize, however, that the embodiment(s) of the present invention that are described and shown herein are only examples of specific embodiment(s), set out for the purpose of describing the making and using of the present invention, and that the embodiment(s) shown and/or described herein are not the only embodiment(s) of a method and apparatus constructed and/or performed in accordance with the teachings of the present invention.
The present invention is an apparatus for assembling the top and bottom blanks of a foldably-constructed pallet in nested relation comprising an intake for taking up and registering a top blank, an intake for taking up and registering a bottom blank, clamps for folding the registered top and bottom blanks to form support ribs therein; a joiner for compressing the folded top and bottom blanks to each other in nested relation to form the pallet; and a mandrel for folding a strap formed on either of the top or bottom blank into contact with the opposite blank and for inserting the end of the strap into a cut formed in the material comprising the opposite blank for interlocking the top and bottom blanks.
The present invention is also a method for interlocking top and bottom substantially planar members in nested relation comprising the steps of folding a flap formed on a substantially planar top member to a position substantially perpendicular to the planar surface of the top member and folding a flap formed on a substantially planar bottom member to a position substantially perpendicular to the planar surface of the bottom member, the flap on the top member forming a sidewall and the flap on the bottom member forming an end wall when the top and bottom members are in nested relation. A strap extending from either the flap forming the sidewall or the flap forming an end wall is then folded around the corner formed by the end wall and sidewall and the end of the strap is inserted into a slot formed in the other of the sidewall or the end wall and the end of the strap is retained in the slot.
In another aspect, a method of resisting torsional force exerted on a force resisting structure comprised of top and bottom substantially planar members, either or both of the top and bottom planar members having folded portions forming sidewalls when and assembled to each other in nested relation, comprising the steps of folding a strap formed integrally with the top member into contact with the bottom member and inserting a tab formed on the end of the strap into a cut formed on the bottom member. A tab formed on the end of the strap is then retained in the cut.
Referring to the figures,
Turning to the drawings, wherein like reference numerals designate identical or corresponding parts,
As explained further below, each blank 50, 70 has foldable portions foldable along fold or crease lines defined or formed in the blanks in order to foldably construct or assemble the top and bottom members. Each blank 50, 70 is provided, where necessary, with cut lines creating separable edges in the blanks for various purposes including to define or form the foldable portions and/or other structural elements, and/or to allow for or facilitate folding of the foldable portions. The cut lines can be formed as complete cuts extending entirely through the thickness of the sheet material to form completely severed separable edges. Alternatively, the cut lines can be formed as partial cuts, such as perforations or score lines, extending partly through the thickness of the sheet material comprising blanks 50, 70 to form partly severed, separable edges that can be severed completely during foldable construction or assembly. Either or both blanks 50, 70 may be provided with one or more cut-out windows of various shapes and sizes where the sheet material is partially removed or is completely removed during foldable construction or assembly to serve various purposes. Some of the purposes that may be served by the provision of cut-out windows include simplifying the manufacture or preparation of the blanks, facilitating foldable construction or assembly of the force-resisting structure, allowing for interlocking engagement between portions of the same or different blanks, and reducing weight when possible without sacrificing structural strength. The peripheral dimensions and thickness of the blanks 50, 70 and the location of the fold lines, cut lines and cut-out windows can vary in accordance with the features desired for the force-resisting structure 30 based on its intended application.
The pallet bottom 50 of pallet 30 is shown in the assembly process with ribs folded up in
The pallet top 70 of pallet 30 is shown in the assembly process with ribs folded down in
After the rib sets 51, 71 re formed in both the pallet bottom 50 and pallet top 70, the top and bottom 50, 70 are brought together and aligned as shown in
After assembling the rib sets 51, 71 of the pallet bottom 50 and pallet top 70 together, the outer edge of the pallet 30 is assembled. The assembly steps are set out in detail in Ser. No. 13/134092 and briefly shown in
The pallet bottom 50 and pallet top 70 are then locked together to provide a strong and reliable load carrying capability with the completed pallet 30 as shown in
To assemble the interlock, and as shown in more detail in
As best shown in
As noted above, the interlocking arrangement of the present invention is, in one embodiment, designed for automated assembly, and the assembly steps are set out in sequence in
A third embodiment of the locking arrangement, or corner lock, is shown in
As best shown in
As best shown in
It will be appreciated that, although described herein as being located in the wall segment 1136A of the side wall 1136 of top member 1112, wall segment 1137A of the side wall 1137 of bottom member 1113 is likewise provided with a locking slot, knife cut(s), and beveled flaps. However, because the structure in wall segment 1137A is not visible in the perspective view shown in
The notches 1178 located near the distal end of locking strap 1163 define the above-described locking formation 1166 and serve at least two functions. First, notches 1178 are aligned with the point at which mandrel 1168 engages the outside surface of locking strap 1163, as well as the opening to locking slot 1161, to provide a point of weakness along which the material comprising locking strap 1163 deforms as the portion of locking strap 1163 comprised of locking formation 1166 is driven through the locking slot 1161 past the deflecting flaps 1172, thereby allowing the locking formation 1166 to be inserted through locking slot 1161. Second, after locking formation 1166 has been driven through locking slot 1161, top and bottom members 1112, 1113 are interlocked in the sense that any attempt to pull locking formation 1166 back out of locking slot 1161 causes the surfaces 1180 formed by the notches 1178 in the material comprising locking strap 1163 to engage the edges of locking slot 1161, the surfaces 1180 acting as stops to resist movement of the locking formation 1166 back out of locking slot 1163. As noted above, knife cuts 1171 are not considered essential to the function of the interlocking fastening element of the present invention, but if those cuts 1171 are utilized, they provide an additional advantage such that the preferred embodiment of the invention includes the cuts 1171. Specifically, when a force is exerted on either the top or bottom member 1112, 1113 that causes the two members to tend to separate from each other such that locking formation 1166 is pulled in a direction out of locking slot 1161, the stop surfaces 1180 engage the back side of the material comprising the wall segments 1136 and/or 1137 near the knife cuts 1171. As a result of the engagement of the stop surfaces 1180 and the material comprising the wall segments 1136, 1137 near knife cuts 1171, the material comprising wall segments 1136, 1137 deflects outwardly at knife cuts 1171, thereby reducing the tendency of stop surfaces 1180 to wear and/or deform. Over repeated cycles of the pulling of locking formation 1166 out of locking slot 1161, the deflection of the material comprising wall segments 1136, 1137 at knife cuts 1171 substantially reduces the likelihood that the corners of stop surfaces 1180 will be worn, deformed, or even sheared off, to the point that they do not function to resist movement of locking formation 1166 back out of locking slot 1163.
It should be appreciated that the locking arrangement can be used to interlock various overlapping side walls of the top and bottom members at the corners or at other locations along the side walls (the interlocking fastening element of the present invention is referred to herein as a “corner lock” only because it is located at the corner of the preferred embodiment of a force resisting structure, not because it must be located at a corner). It should also be appreciated by those skilled in the art who have the benefit of this disclosure that the insertion of a tab 166 (
(
Structural strength, rigidity and integrity, including increased torsional strength and load support strength, are enhanced because the portions of the top and bottom members that interlock, secure or are secured to other portions, and/or provide vertical support for the top member base panel, are formed from the initial blanks of sheet material and remain integral with the blanks. Structural strength, rigidity and integrity, including torsional strength and load support strength, are also enhanced due to the snug fit of the wings, the side wall flaps and/or the vertical support ribs in the interior of the force-resisting structures. The vertical support ribs form “X”-shaped or cross-shaped vertical support structures within the force-resisting structures for enhanced load support strength. The “X”-shaped or cross-shaped vertical support structures are formed by interlocking top and bottom support ribs or by support ribs provided in either the top or bottom member. The force-resisting structures are designed so that loads are supported along the lines of corrugation of the sheet material for greater strength, rigidity and integrity, including greater torsional strength and load support strength. The side wall flaps and/or the wings are arranged to provide vertical support entirely around the perimeter of the force-resisting structures to resist deflection of the top member base panel. The side portions of the top and bottom members include side walls, with or without tuck flaps, and/or retention elements and the side walls are either continuous or formed as side wall segments separated by spaces. The side walls of the bottom members fit interiorly of side walls of the top members when the top and bottom members are in nested relation. Alternatively, the side walls of the top members fit interiorly of the side walls of the bottom members in nested relation. The side walls of the top and bottom members are secured in overlapping relation and a locking arrangement formed from the initial blank is used to secure overlapping side walls, especially at the corners of the force-resisting structures. The top and bottom members are easily manufactured and shipped and/or stored in the unfolded condition in which the top and bottom members occupy minimal space due to their flat or planar configuration. The force-resisting structures are disassembled or broken down for return to the unfolded condition subsequent to use and are readily and easily recyclable or disposable. Accordingly, the force-resisting structures minimize adverse environmental impact, occupy minimal space prior to and/or subsequent to assembly, and effectively save in production, storage and transportation costs.
Referring now to
A schematic diagram of a machine process for use with a corrugated paperboard pallet production machine of
At step 599A, the top and bottom members 50, 70 appear as shown in
Those skilled in the art who have the benefit of this disclosure will also recognize that certain changes can be made to the component parts of the apparatus of the present invention without changing the manner in which those parts function and/or interact to achieve their intended result. For example, rather than using the “L”-shaped mandrel 168 (
Claims
1. A method of resisting torsional force exerted on a force resisting structure comprised of top and bottom substantially planar members, either or both of the top and bottom planar members having folded portions forming sidewalls when and assembled to each other in nested relation, comprising the steps of:
- folding a strap formed integrally with the bottom member into contact with the top member;
- inserting a tab formed on the end of the strap into a cut formed on the top member; and
- retaining the tab formed on the end of the strap in the cut.
2. The method of claim 1 wherein a strap formed integrally with the top member is folded into contact with the bottom member for inserting a tab formed on the end of the strap into and retaining within a cut formed on the bottom member.
3. The method of claim 1 wherein the tab formed on the end of the strap is driven through the cut by a mandrel that engages the strap.
4. The method of claim 1 wherein the tab formed on the end of the strap is retained in the cut by a mechanical fastener.
5. The method of claim 1 wherein the tab formed on the end of the strap is retained in the cut by contact between the tab and the material comprising the top member that is deflected by insertion of the tab into the cut.
6. The method of claim 1 wherein the tab is retained in the cut by engagement of the material comprising the top member by notches formed in the strap.
7. The method of claim 1 wherein the strap is folded into contact with the top side of the top member.
8. The method of claim 7 wherein the cut formed on the top member is formed on the top side of the top member.
9. The method of claim 1 additionally comprising the steps of:
- folding a strap formed integrally with the top member into contact with the bottom member;
- inserting a tab formed on the end of the top member strap into a cut formed on the bottom member; and
- retaining the tab formed on the end of the top member strap in the cut formed in the bottom member.
10. The method of claim 10 wherein the strap formed integrally with the top member is folded into contact with the bottom member on one side of the corner formed by the sidewalls of the top and bottom members and the strap formed integrally with the bottom member is folded into contact with the top member on the other side of the corner formed by the sidewalls of the top and bottom members.
11. An interlock for the top and bottom members of a foldably-constructed pallet comprising:
- a strap integral with the material comprising one or both of the top and bottom members of a foldably-constructed pallet, one or both of the top or bottom members being folded to form sidewalls when assembled to each other to form a pallet;
- a locking formation formed on the end of said strap;
- a knife cut in the material comprising the opposite bottom or top member for receiving the locking formation, said strap being folded over the sidewall and into contact with the opposite bottom or top member with the locking formation inserted into the knife cut at the corner of the pallet.
12. The interlock of claim 11 wherein a portion of the material comprising the top or bottom members bears against the locking formation when the locking formation is inserted into the knife cut.
13. The interlock of claim 11 additionally comprising means for retaining the locking formation in the knife cut.
14. The interlock of claim 13 wherein said locking formation retaining means comprises a notch formed on the locking formation for bearing against the material comprising the top or bottom member when the locking formation is inserted into the knife cut therein.
15. The interlock of claim 13 wherein said locking formation retaining means comprises a retaining tab formed when the locking formation is inserted into the knife cut therein.
16. The interlock of claim 11 wherein both top and bottom members are provided with a respective locking strap, the locking strap integral with the top member being folded over the sidewall on one side of the corner of the pallet and the locking strap integral with the bottom member being folded over the sidewall of the other side of the corner of the pallet.
17. A method of interlocking top and bottom substantially planar members in nested relation comprising the steps of:
- folding a flap formed on a substantially planar top member to a position substantially perpendicular to the planar surface of the top member;
- folding a flap formed on a substantially planar bottom member to a position substantially perpendicular to the planar surface of the bottom member, the flap on the top member forming a sidewall and the flap on the bottom member forming an end wall when the top and bottom members are in nested relation;
- folding a strap extending from either the flap forming the sidewall or the flap forming an end wall around the corner formed by the end wall and sidewall;
- inserting the end of the strap into a slot formed in the other of the sidewall or the end wall; and
- retaining the end of the strap in the slot.
18. The method of claim 17 wherein the slot is provided with a knife cut extending therefrom, the strap being driven through the slot and knife cut by a mandrel that engages the strap.
19. The method of claim 18 wherein the strap is retained in the slot by interaction of a tab formed on the end of the strap with the corners formed by the knife cut and the slot.
20. The method of claim 18 additionally comprising deflecting the corners formed by the knife cut and the slot in the direction in which the strap is driven by the mandrel to facilitate insertion of the strap into the slot.
21. Apparatus for assembling the top and bottom blanks of a foldably-constructed pallet in nested relation comprising:
- an intake for taking up and registering a top blank;
- an intake for taking up and registering a bottom blank;
- clamps for folding the registered top and bottom blanks to form support ribs therein;
- a joiner for compressing the folded top and bottom blanks to each other in nested relation to form the pallet; and
- a mandrel for folding a strap formed on either of the top or bottom blank into contact with the opposite blank and for inserting the end of the strap into a cut formed in the material comprising the opposite blank for interlocking the top and bottom blanks.
22. The apparatus of claim 21 additionally comprising a programmable controller for regulating each of said top intake, said bottom intake, said clamps, said joiner, and said mandrel.
23. The apparatus of claim 21 additionally comprising clamps for folding said top and bottom blanks to form sidewalls, the strap being folded into contact with the opposite blank at the corner formed by adjacent sidewalls.
Type: Application
Filed: Jun 26, 2013
Publication Date: Oct 20, 2016
Applicant: DESIGN PALLETS, INC. (APOPKA, FL)
Inventors: Douglas A. OLVEY (Longwood, FL), James L. SKETO (Mableton, GA)
Application Number: 14/410,057