Note: Descriptions are shown in the official language in which they were submitted.
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CORRUGATED SHIPPING PALLET AND SUPPORT MEMBER
FIELD OF THE INVENTION
The present invention relates to support members which can be
used as a substitute for wood logs, boards, or planking. The support
members are preferably constructed from corrugated paper and are
lightweight while having high strength. The support members can be
utilized to brace, stabilize, or support various items.
The present invention relates to a pallet or load carrying structure
which can be manufactured from corrugated paper or similar materials
which are recyclable. The pallets are utilized to carry goods, materials,
etc. and are advantageously lightweight, thus saving transportation costs.
The structure of the pallet provides excellent stability and yet allows for
production costs to be minimized.
BACKGROUND OF THE INVENTION
Industries such as transportation and manufacturing have for years
utilized wood articles such as logs, boards, and planking as supports,
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braces, and separators for various goods or other materials. While wood
articles have been known to be durable, they have numerous drawbacks.
Disadvantages include that wood is relatively dense and thus
heavy. The weight of wood articles increases transportation costs and
reduces the amount of materials which can be transported. A further
disadvantage is that wood surfaces are rough and generally uneven
which can damage the finish of materials, especially fragile materials,
abutted or supported thereby. Moreover, when exposed to moisture,
wood articles can warp, becoming unlevel and not suitable for intended
uses.
A pallet is a portable platform generally including a planar
horizontal member, which can be used as a base member for stacking,
storing, handling and transporting materia?s or goods. Generally, pallets
are constructed from wood and nails or staples. Recently, pallets have
also been constructed from paper-based materials and plastics. Pallets
generally have openings in the structure thereof to accommodate the
forks of a forklift truck, or the like, and allow the pallet to be lifted off
a
floor.
U.S. Patent No. 5,269,219 relates to a pallet design for
transporting loads fabricated from paper products consisting of a load-
supporting deck, a top cover sheet with tuck tabs that provides a
fastening and link to the runners, a bottom sheet glued to the deck that
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provides a solid surface to attach the runners, and runners spaced apart
and at the appropriate height to provide access to the forks on a forklift
or hand jack.
U.S. Patent No. 5,595,125 relates to a lightweight, disposable,
corrugated paper pallet formed by a plurality of corrugated paper runners,
traversing the length of the pallet, each runner enveloped by a
continuous corrugated paper inner sheet, which itself is bonded to the
lower side of a reinforced corrugated paper top deck and to the upper
side of a corrugated paper bottom stabilizing deck.
U.S. Patent No. 5,784,971 relates to a collapsible pallet assembly
structure which includes at least a pair of lengthwise beam members and
at least a pair of crosswise beam members formed of a corrugated paper
materia~. Each lengthwise bead men-~ber includes a surface plate pQrtion
from which a plurality of folded sidewall portions extend downward and
at least one wing piece portion projects in substantially coplanar manner.
The surface plate portion has formed therethrough a plurality of upper
slot holes which communicate respectively with a plurality of lower slot
holes formed through the sidewall portions. Each crosswise beam
member includes a top plate portion from which a plurality of folded
bracket plate portions extend downward. Each bracket plate portion
includes a slotted opening that delineates a pair of bracket plate
extending sections. Each crosswise beam member is coupled to the
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lengthwise beam members in a transverse manner with its top plate
portions partially overlaying at least one of the lengthwise beam
members surface plate portions and with at least one extending section
of each bracket plate portion inserted through an upper slot hole of a
lengthwise beam member surface plate portion.
U.S. Patent No. 5,934,202 relates to a paper pallet which includes
a bottom deck board made of a corrugated paper board, a top deckboard
made of a corrugated paper board, a plurality of paper blocks
longitudinally and transversely arranged in rows and connected between
the bottom deckboard and the top deckboard, and a plurality of paper
packing members respectively adhered between the paper blocks and
one of the bottom deckboard and the top deckboard, the packing
members each having an elongated base adhered between one of the
bottom deckboard and the top deckboard and one row of the paper
blocks and pairs of packing flaps bilaterally extended from two opposite
long sides of the elongated base and respectively adhered to the
corresponding row of blocks at two opposite sides.
U.S. Patent No. 6,357,364 relates to a paper pallet comprising
support blocks, a top pad and a wrap. The support blocks are of a comb
configuration, e.g., honeycomb or hexacomb. The top pad is of a
corrugated material and is positioned above the support blocks. The
wrap is also of a corrugated material and wraps, via direct contact, the
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top and side surfaces of the top pad as well as wrapping, via direct
contact, at least two side surfaces of the support blocks.
The prior art paper-based pallets present rather complicated
designs which are not cost effective to produce and are relatively bulky
and heavy. The pallets of the prior art are labor intensive and often not
completely recyclable.
SUMMARY OF THE INVENTION
Support members are disclosed which can be employed as
substitutes for wood braces, supports, or the like. The support members
are preferably constructed from corrugated paper and have a high
strength to weight ratio. The support member is generally formed from
single face corrugated which is wound around a central area or core to
form an elongated body having dimensions similar to the wood article it
can replace.
In a further embodiment, an object of the present invention is to
provide a pallet, preferably constructed of corrugated paper, which while
being lightweight has sufficient strength to support materials or goods to
be transported. Advantageously, the pallet can be recycled and poses
no harmful effects on the environment.
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A further object of the invention is a pallet structure that is easily
customizable and can be manufactured in a vast number of size ranges
to suit the varying needs of customers.
The pallet of the present invention generally comprises an upper
deck member, a lower deck member, and a plurality of support members
connected therebetween. The upper deck member and the lower deck
member, independently, are disposed at a horizontal plane substantially
parallel to each other as well as a ground surface. The support members
comprise a single continuous wind of corrugated paper linerboard, which
is preferably single faced, having a continuous layer of paper with
strengthening flutes attached thereto. The continuous wind of the
support members provides strength and rigidity to the pallet.
In one embodiment, the pallet is constructed from two or more
support members which substantially extend the length or width of the
deck members and allow two-way access for a forklift truck. In a further
embodiment, the support members include access holes perpendicular to
the longitudinal axis thereof so that the pallet can be accessed from all
four sides for lifting and/or moving.
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BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and other features and
advantages will become apparent by reading the detailed description of
the invention, taken together with the drawings, wherein:
FIG. 1 is a perspective view of a corrugated paper pallet of the
present invention showing the upper and lower deck members connected
by support members.
FIG. 2 is an exploded view of a pallet showing the continuous
wind or wrap of the support members.
FIG. 3 is a partial perspective view of a pallet with removed
portions to particularly illustrate the orientation of the flutes of the
corrugated members.
FIG. 4 is a perspective view of a support member which can be
utilized as a substitute for wood pieces.
DETAILED DESCRIPTION OF THE INVENTION
The embodiments of the pallet and associated components thereof
according to the present invention will be specifically described, with
reference to the drawings wherein like numerals indicate like or
corresponding parts throughout the Figures.
FIG. 1 illustrates a pallet 10 of the present invention which
comprises an upper or top deck member 20, a lower or bottom deck
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member 30, and a plurality of support members 40. The support
members are secured at predetermined locations between the deck
members by a securing means, such as adhesive, tape, fasteners, or the
like, with common white glue being preferred.
The upper deck member 10 typically serves as a support or load-
bearing surface for the goods or materials adapted to be stored on and/or
transported by the pallet. The upper deck member is preferably formed
from a single sheet of corrugated linerboard paper. The corrugated paper
can be single wall, double wall or triple wall. As known in the art, single
wall corrugated sheets are formed from two face sheets, 22, 24
connected by a layer of flutes 26, as shown in FIG. 3. The individual
double wall and triple wall corrugated sheets include two and three
layers of fluting, respectively, each separated by a single layer of thin
paper or sheeting, with a layer of the paper or sheeting covering the
outer surfaces of the outer flutes. Accordingly, the double and triple
wall corrugated sheets have alternating layers of flutes and thin paper
layers, with the paper layers being the outer surface of the sheets. The
flutes can be described as having a repeating "S" shaped pattern or
wave profile. The height of the flutes, i.e., from peak to trough, can
vary as known in the art and can be, but are not limited to, A, B, C, and
E grade. When double or greater wall corrugated sheet is utilized,
different grade and thus different heights of flutes can be used in a
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single sheet of the corrugated paper, with B and C grade preferred for
double wall sheets and A, B, and C; or A, C, and C preferred for triple
wall. The flutes of the corrugated sheeting form hollow tube or straw-
like passageways and connect the remaining layers together.
Top deck member 20 is a planar structure having a predetermined
length and width, with sizes for both ranging generally from about 12 or
14 to about 50 inches, and preferably from about 30 or 40 to about 48
inches.
The main plane formed by the upper deck member is substantially
horizontal and parallel to the lower deck member and adapted to be
parallel with a ground surface. The top member is maintained a
predetermined distance, usually about 3 to about 5 or 6 inches from the
lower deck member 30. -
The lower deck member 30 can be formed in the same size,
manner and construction as the upper deck member 20.. Depending on
the intended use of the pallet, the corrugated sheets of the upper and
lower deck members can be the same or different such as both being
single wall corrugated paper, or one member being single wall and the
other triple wall, etc. The lower deck member contacts or rests upon the
ground surface. The planes formed by the upper and lower deck
members are, as noted, substantially parallel and thus provide a level
surface for goods or materials.
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The support member or stringers 40 of the pallet provide both
strength and rigidity to the structure. Each individual support member is
formed from a single continuous piece of corrugated paper, such as
single face. Alternatively, a plurality of pieces such as generally about
10 or about 8 or less, desirably about 6 or about 4 or less, and
preferably about 3 or about 2, can be utilized and the same are butted at
their ends to one another, either with or without a fastener such as an
adhesive and wound in the same manner as a single continuous piece of
corrugated paper. The continuous piece of a predetermined height is
wound or wrapped in a direction around itself to form a predetermined
length and width or thickness. Support member 40 is preferably formed
from single face corrugated paper comprising a single layer of paper with
flutes co-extending therewith. Glue or other adhesive is utilized to
secure the continuously wound layers to each other. During formation of
the support member, the glue is preferably applied to the outer flute
edges that will contact the succeeding paper layer. The continuous wind
has a continuous nature of alternating layers of flute and liner or paper.
The overall size of a support member 40 can vary with the height
ranging generally from about 3 inches to about 5 or about 6 inches,
desirably from about 3.5 to about 4 inches, and preferably about 3.5
inches; the width ranging generally from about 2 to about 4 or about 6
inches, desirably from about 2 to about 3 inches, and preferably from
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about 2 to about 2.5 inches; and the length ranging generally from 12 or
14 to about 50 inches; desirably from about 40 to about 48 inches and
preferably from about 46 to about 48 inches.
The support member flutes are arranged parallel to the height of
the support member to provide strength. In this manner, the deck
members will cover the open ends of the support member, which are
then fully enclosed. The overall dimensions of a support member will
vary and depend on the intended use and weight the pallet will be used
to support.
Often a support member will run substantially the entire length of
a pallet from one side or end to another. The number of support
members utilized between the deck members will also depend on the
weight that needs to be supported, and preferably about 2 or about 3 to
about 6 support members are utilized in a pallet.
In a preferred embodiment, the flutes.26, 36 of the deck members
30,40 are disposed in a direction perpendicular to the longest length (as
opposed to the width) of the support members, thus providing strength
to the pallet as shown in FIG. 3. Thus, the flutes of the support
members are perpendicular to the flutes of the deck members. This
configuration is also illustrated in FIG. 2 and has been found to provide a
lightweight, recyclable pallet which is strong and sturdy in construction.
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As shown at least in FIG. 2, support members 40 preferably have
rounded or curved end portions 42. The curved end portions are adapted
to guide the forks of a fork lift truck into the pallet. This is, the curved
end portions will allow the forks to slide into the passageways formed
between adjacent support members.
FIG. 3 is a detailed cross-sectional view of a pallet of the present
invention, particularly illustrating the orientation of the flutes of the
corrugated members. The flutes 26 of the upper deck member 20 are
orientated in a direction perpendicular to the length of support member
40. The upper deck member is a single wall corrugated paper sheet
having face paper layers or sheets 22 and 24 connected by flutes 26. In
a similar manner, the lower deck member includes face paper layers or
-sheets--32 and 34 connected by flutes 36, which arc also orientated
perpendicular to the length of support member 40.
FIG. 4 illustrates a support member 40 which can be utilized to
create a four-way entry pallet. Support member 40 includes at least two
cut-outs 44 which extend completely through the width of the support
member. The size of the orifice or cut-outs can vary and are at least
large enough to accommodate a fork of a fork lift truck. The cut-outs 44
enable the pallet of the present invention to be entered from all four
sides for lifting and moving the same.
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In a further embodiment, as illustrated in FIG. 2, the lower deck
member 30 can have jack holes 50 formed therein to accommodate lift
wheels of a hand jack. The jack holes 50 can be formed of any shape or
size and are generally at least adapted to be larger than the size of the
lift wheels of the hand jack. Jack holes 50 allow the pallets to be
utilized and lifted by hand jacks which are generally manually operated.
The hand jacks generally include wheels on the fork portions for rolling
movement across the ground surface. The jack holes 50 are adapted to
allow the wheels of a hand jack to be freely moved, as the wheels are
prevented from contacting the pallet 10 due to the presence of the
jackholes.
Additionally, either or both of the upper and lower deck members
can be treated with-an oil.and/or -water repellent compositions as kno;v,.~an
in the art and to the literature to prolong the life of the pallet. The
pallets of the present invention being formed of corrugated paper are
completely recyclable and are thus beneficial to the environment. The
construction of the pallet also renders the same insect resistant.
In a further embodiment, a support member or article can be
utilized alone, that is not in a pallet assembly. The support member is
used as a wood substitute and is used as, but not limited to, stack
separators, supports, spacers, braces, stabilizers, and the like.
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As stated hereinabove, the support members 40 are generally
elongated in length as shown in at least FIG. 4. In addition to the above-
noted size ranges for the support members used in a pallet assembly,
support member construction is versatile and thus a support member is
sized accordingly to fit an intended application. For example, in one
embodiment the support member is used as a brace on the floor of a
truck trailer or rail car; or used between adjacent items or rows of items.
The support member 40 is formed in sizes of about 0.50 x about 2 x
about 2 inches to about 8 x about 8 x about 50 or about 100 inches or
from about 1 x about 2 x about 2 inches to about 6 x about 6 x about
50 inches. In further embodiments, the support member is also be
manufactured to typical wood board specifications similar to 2" x 4", 4"
-x-4``, or 2 - x 6" in substantially any desired length: In one
embddin')(~Fnt,
two or more support members are glued together, i.e., side by side, one
on top of the other, or the like if desired to provide a larger surface area.
Although the relative size of the support member can vary, the
construction method is generally the same. The support member is
formed as a wind or coil of corrugated paper. The wind is considered a
spiral wind, more specifically a flattened, elongated wind or coil. As
disclosed hereinabove, the support member is preferably formed from
single face corrugated paper having a corrugated paper layer of a
predetermined thickness and a flute layer attached thereto; typically with
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an adhesive as known in the art. The assembled flattened, spirally
wound or rounded end rectangular support member has alternating layers
of paper sheet and fluting.
As stated hereinabove, the flutes can be, but are not limited to, A,
B, C, or E grade. The paper layer of the corrugated paper generally
ranges from about 23 to about 90-pounds per msf (thousand square
feet) in medium or linerboard as known in the art. Advantageously, the
weight or thickness of the paper is exactly tailored to fit the desired end
use, wherein if more support or strength is needed, a heavier grade of
paper is utilized. Thus, the support members can be custom tailored to
specific applications.
The support member 40 is generally formed in the following
manner. Starting. with = a first end 4-1, corrugated paper Of; a
predetermined height is extended a predetermined length "X" forming a
central area or core 42, preferably in a straight line so that when a
predetermined number of layers are wrapped or wound around the
central core, a support member is formed having a total length L and
width W. When the corrugated paper has been extended to length "X,"
the paper is then bent or folded either clockwise or counter-clockwise
and routed back along and adhered to central core 42. When the first
end 41 is reached, the corrugated paper is wrapped therearound. The
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process is repeated until the central area is wrapped with a desired
number of layers.
Each layer of paper of the support member is preferably adhered to
an adjacent layer with an adhesive. As illustrated in the FIG. 4, the flute
layers and sheet layers alternate. End 43 of the corrugated paper can be
essentially located at any point along the outside of the support member,
and is not limited as shown in FIG. 4. While the support member can be
formed from a single piece of corrugated paper, it should be understood
that more than one piece can be utilized with ends being abutted or even
slightly overlapped.
The support member of the present invention has excellent
strength. The wrapped structure provides rigidity and stability to the
~ support member. The curved end portion 45 is very steble and aids in~
preventing separation between the layers. The support member is used
wherever bracing, support or the like are needed. The support member
provides cushioning properties and absorbs vibrations which can occur in
transit, thereby reducing damage to a product. Moreover, the support
member is free of nails, splinters, or other protrusions harmful to
products which can be supported thereby. The support members are
recyclable and repulpable, thereby reducing waste in landfills.
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EXAMPLES
Example 1
A two-way entry pallet of the present invention was constructed
having an upper deck, a lower deck, and four support members. Both
the upper deck and lower deck had dimensions of 40 inches wide by 48
inches long and were formed from a single sheet of single wall
corrugated pap'er, 75-pound version. The support members were each
constructed from a single sheet of single face corrugated paper. Glue
was applied to the flute edges and the single piece of single face
corrugated paper was wrapped around itself to form a support member
3% inches high, 48 inches long and 2 inches wide. Two support
members were placed at the width ends with the remaining supports
being-- disposed -Al~erebetween at equal distance intervals from: tbe,
remaining support members. The deck members were adhered to the
support members utilizing common white glue.
7,200 pounds of weight was placed on the pallet. The pallet
maintained its initial shape and dimensions and did not deform under the
pressure of the weight for two weeks when the load was removed.
Example 2 - Compression Test
A pallet having the above-noted construction and dimensions as iri
Example 1 was placed in a gauged hydraulic press. Pressure was then
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applied to the top and bottom deck members of the pallet and increased
incrementally. The pallet withstood 17,000 pounds of pressure before
being compressed.
While in accordance with patent statutes the best mode and
preferred embodiment have been set forth, the scope of the invention is
not limited thereto, but rather by the scope of the attached claims.
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