U.S. patent application number 09/730879 was filed with the patent office on 2002-06-13 for three-piece lightweight glueless pallet.
Invention is credited to Olvey, Douglas A., Olvey, Susan O..
Application Number | 20020069796 09/730879 |
Document ID | / |
Family ID | 24937152 |
Filed Date | 2002-06-13 |
United States Patent
Application |
20020069796 |
Kind Code |
A1 |
Olvey, Douglas A. ; et
al. |
June 13, 2002 |
Three-piece lightweight glueless pallet
Abstract
A three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels of essentially rectangular configuration, with a plurality
of longitudinally disposed structural members created on the inner
surface of each panel. During the creation of a basic pallet
member, one of the panels is turned such that its structural
members are disposed in an angular relationship to the structural
members of the other of the panels. A spaced plurality of slots are
formed in the structural members of each basic panel member, with
such slots in the structural members of one panel positioned to
coincide with the slots of the structural members of the other
panel, so that when the two panels are aligned and pushed together,
the slots of the structural members of one panel enter and interfit
with respective slots of the other panel. The interfitted panels,
upon thereafter being placed inside an encapsulating member
constructed of lightweight material, form an integral, three-piece
pallet unit of considerable strength. Preferably the plurality of
longitudinally disposed structural members are made up of separate,
longitudinally extending legs whose inner surfaces have been
secured together either by adhesive means or by mechanical means.
Generally rectangularly shaped apertures are provided in the basic
pallet member that are intended to receive the forks of a fork lift
truck, which apertures align with similar apertures in said
encapsulating member at such time as latter member is installed
around said basic pallet member.
Inventors: |
Olvey, Douglas A.;
(Longwood, FL) ; Olvey, Susan O.; (Fairburn,
GA) |
Correspondence
Address: |
Julian C. Renfro, Esquire
Post Office Box 2601
Winter Park
FL
32790-2601
US
|
Family ID: |
24937152 |
Appl. No.: |
09/730879 |
Filed: |
December 7, 2000 |
Current U.S.
Class: |
108/56.1 |
Current CPC
Class: |
B65D 2519/00054
20130101; B65D 2519/00019 20130101; B65D 2519/00273 20130101; B65D
2519/00567 20130101; B65D 2519/00288 20130101; B65D 2519/00378
20130101; B65D 2519/00562 20130101; B65D 2519/00442 20130101; B65D
19/0059 20130101; B65D 2519/00318 20130101; B65D 2519/00278
20130101; B65D 19/0012 20130101; B65D 2519/00124 20130101; B65D
2519/00343 20130101; B65D 2519/00557 20130101; B65D 2519/00437
20130101 |
Class at
Publication: |
108/56.1 |
International
Class: |
B65D 019/38 |
Claims
We claim:
1. A three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels of essentially rectangular configuration, with each of said
panels having ends and sides and with said ends residing in an
essentially parallel relationship, a plurality of parallel,
longitudinally disposed structural members created on the inner
surface of each panel, during the creation of a basic pallet member
by the use of said panels, one of said panels being turned such
that its structural members are disposed in an angular relationship
to the structural members of the other of said panels, a plurality
of slots formed at spaced locations in the structural members of
each basic panel member, with such slots in the structural members
of one panel positioned so as to coincide with the location of said
structural members of the other panel, so that when the two panels
are pushed together in an aligned relationship, the slots of the
structural members of one panel enter and interfit with respective
slots of the other panel, said interfitted panels, upon thereafter
being placed inside an encapsulating member constructed of
lightweight material, forming an integral, three-piece pallet unit
of considerable strength.
2. A three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which each of said plurality of parallel,
longitudinally disposed structural members is made up of separate,
longitudinally extending legs whose inner surfaces have been
secured together.
3. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 2 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
adhesive means.
4. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 2 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
mechanical means.
5. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 4 in which the mechanical means by which said
inner surfaces of said longitudinally disposed structural members
are secured together involves the use of interlocking tabs.
6. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which said plurality of slots formed at
spaced locations in the structural members of one of said basic
panel members are of approximately the same depth as the slots
formed in the structural members of the other of said basic panel
members.
7. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which said plurality of slots formed at
spaced locations in the structural members of one of said basic
panel members are of a somewhat different depth than the slots
formed in the structural members of the other of said basic panel
members.
8. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which at least one of said longitudinally
disposed structural members is disposed on one side of a centerline
location that is parallel to and substantially equidistant from the
ends of each panel, and another of said longitudinally disposed
structural members is disposed at a corresponding location on the
other side of said centerline location.
9. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which a plurality of longitudinally
disposed structural members are disposed on each side of said
centerline location.
10. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which at least one of said longitudinally
disposed structural members is disposed on one side of a centerline
location that is parallel to and substantially equidistant from the
ends of each panel, and a plurality of said longitudinally disposed
structural members are disposed on the other side of said
centerline location.
11. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which during the creation of a basic
pallet member by the use of said panels, one of said panels is
turned such that its structural members are disposed in an
orthogonal relation to the structural members of the other of said
panels.
12. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which said encapsulating member involves a
central portion equipped with flaps, with two of said flaps being
major flaps provided with locking tabs, and at least two
tab-receiving slots provided in said basic pallet member for
receiving said locking tabs at such time as said basic pallet
member has been placed upon said central portion and said major
flaps have been folded to enclose said basic pallet member.
13. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 12 in which said tab-receiving slots provided
in said basic pallet member for receiving said locking tabs are
located on the centerline of said basic pallet member.
14. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 1 in which each of said panels as well as said
encapsulating member are made from corrugated paperboard.
15. A three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels of essentially rectangular configuration, with each of said
panels having ends and sides and with said ends residing in an
essentially parallel relationship, a plurality of parallel,
longitudinally disposed structural members created on the inner
surface of each panel, a first of said longitudinally disposed
structural members being disposed on one side of a centerline
location parallel to and substantially equidistant from the ends of
each panel, a second of said longitudinally disposed structural
members being disposed on the other side of said centerline
location, during the creation of a basic pallet member by the use
of said panels, one of said panels being turned such that its
structural members are disposed in an orthogonal relation to the
structural members of the other of said panels, a plurality of
slots formed at spaced locations in the structural members of each
basic panel member, with such slots of one panel positioned so as
to coincide with the location of said structural members of the
other panel, so that when the two panels are pushed together in an
aligned relationship, the slots of the structural members of one
panel enter and interfit with respective slots of the other panel,
said interfitted panels, upon thereafter being placed inside an
encapsulating member constructed of lightweight material, forming
an integral pallet unit of considerable strength.
16. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 in which each of said plurality of parallel,
longitudinally disposed structural members are made up of separate,
longitudinally extending legs whose inner surfaces have been
secured together.
17. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 16 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
adhesive means.
18. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 16 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
mechanical means.
19. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 18 in which the mechanical means by which said
inner surfaces of said longitudinally disposed structural members
are secured together involves the use of interlocking tabs.
20. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 in which said first longitudinally disposed
member and said second longitudinally disposed member are disposed
on opposite sides of said centerline location at approximately the
same distance from said centerline location.
21. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 wherein a plurality of longitudinally disposed
structural members are disposed on each side of said centerline
location.
22. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 wherein a different number of longitudinally
disposed structural members are disposed on one side of said
centerline location, than are disposed on the other side of said
centerline location.
23. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 in which said encapsulating member involves a
central portion equipped with flaps, with two of said flaps being
major flaps provided with locking tabs, and at least two
tab-receiving slots provided in said basic pallet member for
receiving said locking tabs at such time as said basic pallet
member has been placed upon said central portion and said major
flaps have been folded to enclose said basic pallet member.
24. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 23 in which said tab-receiving slots are disposed
on the centerline of said basic pallet member.
25. The three-piece lightweight pallet involving the use of a basic
pallet member constructed from a pair of generally flat, die cut
panels utilized in combination with an encapsulating member as
recited in claim 15 in which each of said panels as well as said
encapsulating member are made from corrugated paperboard.
26. A three-piece lightweight pallet involving the use of a basic
pallet member utilized in combination with an encapsulating member,
said basic pallet member being constructed from a pair of generally
flat, die cut panels of essentially rectangular configuration, with
each of said panels having ends and sides and with said ends
residing in a parallel relationship, a plurality of scoring lines
defined in spaced, parallel locations on each of said panels, with
such scoring lines being arranged in closely spaced groups, and
with such scoring lines defining positions at which folding can
take place when the distance between the ends of each panel is
caused to decrease, a first closely spaced group of such scoring
lines being disposed on one side of a centerline location parallel
to and substantially equidistant from the ends of each panel, and a
second closely spaced group of such scoring lines being disposed at
a corresponding location on the other side of said centerline
location, with each of said panels being susceptible to a folding
procedure taking place at each position at which a closely spaced
group of scoring lines are located, said panels, upon the distance
between said ends being caused to decrease so as to bring about
folding at the locations of each closely spaced group of scoring
lines, forming on one surface of each panel, a plurality of
parallel, longitudinally disposed structural members whose inner
surfaces are able to be secured together to resist bending, during
the creation of a basic pallet member by the use of said panels,
one of said panels being turned such that its structural members
are disposed in an angular relation to the structural members of
the other of said panels, a plurality of slots formed at spaced
locations in the structural members of each panel, with such slots
positioned so as to coincide with the location of said structural
members of the other panel, so that when the two panels are pushed
together in an aligned relationship, the slots of the structural
members of one panel enter and interfit with respective slots of
the other panel, with the interfitted panels, upon being joined
together, forming a basic pallet member of considerable strength,
said basic pallet member being utilized in combination with an
encapsulating member of lightweight material designed to readily
receive the basic pallet member.
27. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 26 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
adhesive means.
28. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 26 in which said inner surfaces of said
longitudinally disposed structural members are secured together by
mechanical means.
29. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 28 in which said mechanical means by which the
inner surfaces of said longitudinally disposed structural members
are secured together is by the use of interlocking tabs.
30. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 26 in which said longitudinally disposed
structural members of one panel are disposed in an orthogonal
relationship to the structure members of the other panel.
31. Three two-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 26 in which said encapsulating member involves
a central portion equipped with flaps, with two of said flaps being
major flaps provided with locking tabs, and at least two
tab-receiving slots provided in said basic pallet member for
receiving said locking tabs at such time as said basic pallet
member has been placed upon said central portion and said major
flaps have been folded to enclose said basic pallet member.
32. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 31 in which said tab-receiving slots are
disposed on the centerline of said basic pallet member.
33. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in conjunction with an encapsulating member
as recited in claim 26 in which each of said panels as well as said
encapsulating member are made from corrugated paperboard.
34. The three-piece lightweight pallet involving the use of a basic
pallet member utilized in combination with an encapsulating member
as recited in claim 26 in which generally rectangularly shaped
apertures are provided in said basic pallet member that are
intended to receive the forks of a fork lift truck, which apertures
substantially align with similar apertures in said encapsulating
member at such time as said encapsulating member is installed
around said basic pallet member.
Description
BACKGROUND OF THE INVENTION
[0001] It is well known that pallets, typically made of oak boards
nailed to several spaced apart structural oak members called
stringers, are in extensive use for shipping merchandise, raw
materials and the like. These pallets are used not only in the
United States, but in almost all of the industrial nations of the
world as well. The spacing of the structural oak members or
stringers is such as to define between such members, insert
locations or apertures into which the forks of a forklift truck can
extend, so that the pallet, along with the merchandise or cargo
stacked thereon, can be readily moved from one location to another.
The use of these pallets makes it possible to move the merchandise
or cargo between destination points without it being necessary to
unload and then reload.
[0002] Although these oak pallets are not particularly expensive to
make, typically being constructed from rough oak planking, they are
quite heavy, weighing on the order of 40 pounds apiece. It is
obvious that if literally dozens of pallets upon which merchandise
or cargo has been stacked are loaded upon a cargo aircraft for
delivery to a remote location, there is a sizable weight penalty to
be paid.
[0003] Also as a consequence of the weight of the oak pallets, it
is often not feasible to try to recycle the pallets, so they
frequently are taken to a dump site for destruction or to become
part of a landfill. Because of the large number of pallets being
discarded worldwide, it is a fact that at many landfill locations,
a penalty or surcharge on a perpallet basis is imposed.
[0004] It has been found that most of the items shipped
commercially on pallets do not need or require the considerable
strength afforded by hardwood used in constructing pallets of
conventional configuration, and various attempts have been made to
create hardwood pallets that are lighter than the 40 pound pallets
conventionally used. However, it was found that if the size of the
stringers is diminished too much, it becomes difficult to drive
nails into the stringers, and furthermore, the nails often tend to
pop out and not hold. In other words, it has not proven possible to
reconfigure oak pallets so as to markedly diminish their weight
without seriously diminishing their usability and durability.
Because of this fact it is correct to say that the typical hardwood
pallet is overbuilt for 90% of the loads that are placed on it.
[0005] The Moore U.S. Pat. No. 4,228,744 entitled "Pallet Formed
From Two Spaced, Interlocking Sheets of Corrugated paperboard and
Rigid Sleeves" relates to a pallet formed of paperboard material,
such as two sheets of corrugated paperboard which are cut to define
interlocking tabs spaced in parallel relationship. However, the
Moore pallet is designed for use with only very light loads, and
his design would be entirely insufficient insofar as serving as a
substitute for a conventional oak pallet.
[0006] The Ogilvie, Jr. et al U.S. Pat. No. 6,029,582 entitled
"Force Resisting Corrugated Assembly" represented an improvement in
the field of lightweight pallets not requiring the use of wood,
with this invention involving upper and lower components assembled
by the use of locking slots. The Ogilvie et al invention offers a
disposable pallet that on the one hand can be recycled but on the
other hand that offers strength and durability. In its preferred
embodiment, glue or other adhesive for securing the upper and lower
components together, but unfortunately, the need for glueing the
upper and lower components together represented a step either
requiring the painstaking application of glue or else necessitating
the design of a complex machine. It was obvious that if the need
for glueing the components together could be avoided, this would be
a step forward.
[0007] It is obvious that a continuing need exists for a highly
satisfactory lightweight, low cost pallet requiring no use of glue,
and it is the purpose of this invention to provide such a
pallet.
SUMMARY OF THE INVENTION
[0008] In accordance with this invention we have provided a pallet
of unique design, with it being possible in accordance with this
teaching to create without the use of glue, a lightweight pallet of
corrugated paperboard or similar material, with this pallet being
sufficiently strong for most purposes. Through rigorous testing we
have established that our novel design meets the need for a pallet
enabling merchandise or cargo to be transported to distant
locations without having to pay the considerable weight penalty
necessarily involved when conventional oak pallets are used.
[0009] In the primary embodiment, our novel pallet involves the use
of a basic pallet member utilized in conjunction with an
encapsulating member. The basic pallet member is constructed from a
pair of die cut panels of generally rectangular configuration. On
the inner surface of each panel we have created, by folding, a
plurality of parallel, longitudinally disposed structural members.
Each of the longitudinally disposed structural members is suitably
slotted in a plurality of locations, making it possible for a pair
of generally similar panels to be joined together in a relationship
in which the structural members of one panel are disposed at an
angle, preferably at a right angle, with the structural members of
the other panel.
[0010] Although a lightweight pallet formed of these joined
together panels represents an entity possessing considerable
strength, it is entirely possible that during use, the upper and
lower panel members might tend to separate. Accordingly, it is has
been customary in the past to apply glue or other adhesive to inner
abutting edges of the two panels, so that when the panels have been
assembled in an operative relationship, a very strong unit is
formed that is not likely to come apart.
[0011] Unfortunately, the need to apply glue or other adhesive to
the inner abutting edges of the upper and lower panels causes a
considerable increase in cost. This is because that either
additional labor is required for the application of the glue, or
else it is necessary to resort to a machine design such that glue
is automatically applied at appropriate locations to the inner
surfaces of the members to be joined together. However, to design
this capability into a pallet making machine necessarily causes a
great increase in the cost and complexity of the machine.
[0012] Therefore, we have evolved a highly advantageous design in
which the upper and lower panel members, instead of being glued
together, are only tightly interfitted together to form a basic
pallet member, with this thereafter being followed by placement of
the basic pallet member into a lightweight encapsulating member,
preferably of corrugated paperboard.
[0013] The encapsulating member can be of relatively simple
construction, configured to receive the basic pallet member in what
may be regarded as a central position of the encapsulating member.
The encapsulating member is provided with flaps to be wrapped
around the basic pallet member, with tabs or protrusions created
upon the encapsulating member that are designed to be inserted into
a pair of slots provided in an upper surface of the basic pallet
member. Upon the insertion of the tabs or protrusions into the
slots in the basic pallet member, the encapsulating member is
essentially locked in a surrounding relationship to the basic
pallet member. In this way, a highly versatile, three-piece
lightweight pallet has been created in which no requirement exists
for the glueing of any of the various members together.
[0014] With regard to the creation of the basic pallet member by
the use of the previously mentioned die cut corrugated paperboard
members, it is to be noted that we prefer to create on each member,
several groups of scoring lines, with all of these scoring lines
being in a spaced, parallel relationship. We can use a wide range
of materials in the creation of the basic pallet members, ranging
from light test single wall corrugated paperboard such as 200 pound
test Cflute, up to a heavy grade triple wall corrugated paperboard
such as 1200 pound test triple wall material. In many instances we
prefer the use of 350 pound test, double wall corrugated paperboard
in the construction of the novel panel members, but we are not to
be limited to corrugated paperboard, for we can use a wide range of
other materials, as long as such other material can be cut and
scored and then folded in the manner described herein.
[0015] In the creation of each panel to be folded, we utilize
closely grouped scoring lines, involving at least one
centrally-disposed line. It is possible for the material of the
panel at the location of the centrally-disposed scoring line to be
moved upwardly or downwardly out of the plane of the panel at such
time as the distance between the ends of the panel is caused to
decrease. In this manner, a narrow, elongate leg is created on each
side of the centrally-disposed scoring line.
[0016] Although in accordance with this invention no glue or cement
is required for use between each pair of adjacent, equally sized
legs, each pair of elongate, narrow adjacent legs nevertheless
become relatively rigid in a form we prefer to regard as a
longitudinally disposed structural member that is disposed
perpendicular to the plane of the panel. We may utilize glue,
mechanical means, or other arrangement for assuring the rigidity of
the longitudinally disposed structural members of each panel. The
mechanical means may include staples, or an interlocking tab
arrangement typically involving one or more interlocking tabs
created on one leg of a longitudinally disposed structural member,
and corresponding tab-receiving slots on the other leg of the
structural member.
[0017] It is to be understood that by configuring each generally
rectangularly shaped panel so as to create several groups of
scoring lines, it becomes readily possible, at the time the
distance between the ends of the panel is caused to decrease, to
create a parallel array of these longitudinally disposed structural
members. By creating each group of scoring lines in a properly
spaced relationship with other groups of scoring lines, a desirably
stiff lightweight panel can be created, and in a spacing congruent
with the spacing of the forks of a forklift truck.
[0018] By then selecting a second panel of like construction, and
securing it to the first panel in such a manner that the
longitudinally disposed structural members of the two panels are in
an angular relationship, such as a right angle relationship, it is
possible to create a highly versatile basic pallet member having a
high strength to weight ratio. It is to be understood that we
prefer for the two panels to be joined in an orthogonal
relationship, but we are not to be limited to this. We also prefer
for the longitudinally disposed structural members to be created
perpendicular to the corrugations, but this is not a
requirement.
[0019] Although not quite as strong as a conventional oak pallet,
our novel lightweight, glueless pallet is nevertheless sufficiently
strong for most purposes, and quite advantageously, we can in some
instances employ a number of different techniques for incorporating
certain stiffening into the basic pallet member when particularly
heavy loads are to be carried.
[0020] A highly effective securing together of the two panels
residing in an angular relationship is made possible by providing
appropriately spaced slots or notches in the longitudinally
disposed structural members of both panels, with this slotting
taking place at the locations where the longitudinally disposed
structural members of one panel intersect with the longitudinally
disposed structural members of the other panel. The depth of these
slots is such that the panels can be interfitted together with the
crests of the series of longitudinally disposed structural members
of each panel residing in firm contact with the undersurface of the
other panel. Instead of applying glue to the panels utilized in the
creation of the basic pallet member, we can thereafter encapsulate
the basic pallet member by the use of a simple and inexpensive
overwrap of corrugated paperboard. In this way we can create a
pallet that is strong, inexpensive, and of light weight, typically
weighing less than one-fifth of the weight of an oak pallet of
comparable size and weightcarrying ability.
[0021] It may be noted that the longitudinally disposed structural
members created on each panel of the basic pallet member bear a
slight relationship to an I-beam of the type used in the creation
of buildings, and inasmuch as the crests of the longitudinally
disposed structural members intrinsic to each panel are in firm
contact with the underside of the other panel at the time of panel
joinder to form a basic pallet member, the height of the properly
interfitted panels does not greatly exceed the height of each panel
individually. Because the longitudinally disposed structural
members of one panel are disposed in an angular relationship with
the longitudinally disposed structural members of the other panel,
a grid-like construction is achieved, which has a strength quite
adequate for most loads, but without the severe weight penalty
associated with the use of conventional oak pallets.
[0022] It is therefore a principal object of this invention to
provide a lightweight, glueless three-piece pallet that can be
readily sized to meet the requirements of the load to be
transported, thus avoiding the limitations of a conventional
hardwood pallet, which cannot be constructed economically smaller
or lighter than a certain minimal size and weight.
[0023] It is another object of this invention to provide a novel
lightweight three-piece pallet created from upper and lower panels
placed in a particularly strong, unobvious relationship to create a
basic pallet member that can be utilized inside of a precut
encapsulating member of simple construction, thus entirely
obviating the need for any glue or other securing means in the
creation of a pallet usable with a forklift truck.
[0024] It is still another object of this invention to provide a
very versatile lightweight three-piece pallet that can be readily
configured such that it can be used for a wide variety of purposes,
with no glue or other securing means being required in order to
secure the pallet components together.
[0025] It is yet another object of this invention to provide a
novel lightweight, three-piece pallet in which the configuration of
the pallet can be matched to meet the load requirements of the
product being shipped, so that ample strength will be provided for
a particular location on the pallet where greater support is
desired.
[0026] It is a further object of this invention to provide a
lightweight three-piece pallet in which the upper and lower panels
of the basic pallet member are constructed from lightweight
material in which longitudinally disposed structural members have
advantageously been created, with the longitudinally disposed
structural members of one panel secured in an angular relationship,
preferably an orthogonal relationship, with the longitudinally
disposed structural members of the other panel, so as to create a
particularly strong, gridlike structure that can be readily entered
by the forks of a forklift truck.
[0027] It is a yet further object of this invention to provide a
novel basic pallet member utilized in conjunction with an
encapsulating member, in which both the upper and the lower panels
of the basic pallet member are constructed from corrugated
paperboard that has been folded in a highly effective manner so as
to create a plurality of longitudinally disposed structural members
arranged in a parallel relationship, with the slotted
longitudinally disposed structural members of the upper panel
secured without the use of glue in an interlocked angular
relationship with the slotted, longitudinally disposed structural
members of the lower panel, such that a strong, gridlike
relationship is created.
[0028] These and other objects, features and advantages of this
invention will become more apparent as the description
proceeds.
BRIEF DESCRIPTION OF DRAWINGS
[0029] FIG. 1 is a perspective view of our novel three-piece
lightweight pallet, which consists of a basic, two piece pallet
member that is to be enclosed by a novel encapsulating member, with
this arrangement making the use of glue entirely unnecessary;
[0030] FIG. 2 is a plan view in which the preconfigured
encapsulating member is shown in its spread out or flattened
condition in order to reveal, in considerable detail, the various
scoring lines, flaps and apertures utilized in accordance with this
invention;
[0031] FIG. 3 is a perspective view showing one of the steps taken
in order to bring about the enclosing of the basic pallet member by
the use of the encapsulating member, with it to be noted that a
pair of elongate slots are provided in a central part of the upper
surface of the basic pallet member;
[0032] FIG. 4 is a view generally relatable to FIG. 3 but here
showing the pair of major flaps just before their respective tabs
enter the pair of elongate slots provided in the upper surface of
the basic pallet member;
[0033] FIG. 5 is a perspective view of a basic pallet member
constructed in accordance with this invention having been enclosed
by the encapsulating member, with a foreground portion of the
encapsulating member having been sectioned away to reveal certain
internal construction of the basic pallet member, and making clear
the presence of apertures that may be entered by the forks of a
fork lift truck;
[0034] FIG. 6 is a view similar to FIG. 5 but showing in greater
detail an exemplary embodiment of our basic pallet member,
considered apart from the encapsulating member, with the basic
pallet member having been assembled from panels made of corrugated
paperboard that have been folded in a highly effective manner, with
these panels thereafter assembled with the longitudinally disposed
structural members of one panel disposed in an angular relationship
to the longitudinally disposed structural members of the other
panel;
[0035] FIG. 7 is a plan view of a typical die cut panel prior to
assembly with a like panel, with this view revealing the scoring
lines created thereon in order to permit longitudinally disposed
structural members to be created in a parallel array in accordance
with this invention, with this view also depicting the commencement
of folding along these scoring lines;
[0036] FIG. 8 is a plan view, with a portion fragmented away, that
has been created to a similar scale as utilized in FIG. 7, with
this view revealing an optional arrangement for joining adjacent
legs of the longitudinally disposed structural members together,
with this optional arrangement involving one or more interlocking
tabs utilized on one leg of a narrow, longitudinally disposed
member, and corresponding number of tab-receiving slots utilized on
the other leg of the narrow, longitudinally disposed member, with
each slot disposed in alignment with the corresponding interlocking
tab;
[0037] FIG. 9 is a fragmentary view related to FIG. 8 and showing
to a larger scale, the components of a typical interlocking
tab;
[0038] FIG. 10 is a fragmentary view to a scale similar to that
used in FIG. 9, revealing the wings of an interlocking tab having
passed through the adjacent slot, with these wings thereafter
moving back into a substantially planar relationship in order to
achieve a locking of two adjacent legs together;
[0039] FIG. 11 is a plan view of an encapsulating member generally
along the lines of FIG. 2 but here showing an embodiment containing
suitable apertures, such that the completed pallet can be used with
a pallet jack; and
[0040] FIG. 12 is a perspective view of the basic pallet member
generally along the lines of FIG. 6, but here indicating the use of
apertures in the lower surface of the basic pallet member that
coincide with the apertures in the encapsulating member, such that
the completed pallet can be effectively used with a pallet
jack.
DETAILED DESCRIPTION
[0041] With initial reference to FIG. 1, it can be seen that we
have depicted a first embodiment of our invention, involving a
lightweight, three-piece pallet 10, comprising a basic pallet
member 12 foldably constructed from a pair of generally flat, die
cut panels 14 and 15. It will be noted from this figure that the
basic pallet member 12 resides on a central portion of an
encapsulating member 20, with the basic pallet member and the
encapsulating member together presenting a sturdy, lightweight
three-piece pallet advantageously requiring no glue or adhesive in
its construction.
[0042] As will shortly be discussed at some length, the basic
pallet member 12 has considerable strength in its own right because
of each of the die cut panels 14 and 15 having been previously
folded in a highly advantageous manner, so as to create two or more
longitudinally disposed structural members (not clearly visible in
this figure) that are intrinsic to the panel. Because of this, when
the panels 14 and 15 are assembled together to form the basic
pallet member 12, the longitudinally disposed structural members of
one panel are intended to be disposed at an angle to the
longitudinally disposed structural members of the other panel. As
will be discussed hereinafter, it is preferable for the
longitudinally disposed structural members of one panel to be
disposed in an orthogonal (90.degree.) relationship with the
longitudinally disposed structural members of the other panel, but
we are not to be limited to this.
[0043] As a result of the manner of assembly wherein the
longitudinally disposed structural members of one panel meet in an
angular relationship with the longitudinally disposed structural
members of the other panel, when the panels are properly
interfitted in a glueless manner, a high strength, grid-like
structure is created. Further details of the basic pallet member 12
will be discussed in conjunction with FIG. 6, wherein
longitudinally disposed structural members 140, 142, 144 and 150
are seen to be an intrinsic part of one panel, and longitudinally
disposed structural members 160, 170, 180 and 190 may be seen to be
an intrinsic part of the other panel of the basic pallet
member.
[0044] Because of the highly advantageous manner in which the upper
and lower panels are interfitted, they tend to remain in assembled
relationship, but in the past it has been customary to apply glue
or some other adhesive on abutting interior portions of the panel
members 14 and 15, to prevent their separation during use.
[0045] In accordance with the instant invention, the use of
adhesive between the panel components of the basic pallet member is
made unnecessary, for the previously-mentioned encapsulating member
20 is configured to closely surround the basic pallet member 12,
with tab portions contained on certain edges of the encapsulating
member interfitting with narrow, elongate slots utilized on the
upper surface of the basic pallet member 12. By way of example,
such slots can be placed on the centerline of the basic panel
member, as shown at 36 and 38 in FIG. 1. In this way it becomes
readily possible to lock the encapsulating member around the basic
pallet member in a very secure and stable manner so as to create a
sturdy, durable, easily affordable three-piece unit suitable for
many pallet applications, with the use of glue not being
required.
[0046] With continued reference to FIG. 1, it will be noted that
rectangular apertures are provided in a number of locations, such
as the pair of apertures or openings 16 in the end of the basic
pallet member 12, and the pair of apertures or openings 18 in the
side of the basic pallet member 12. Comparable apertures or
openings are also provided at appropriate locations in the
encapsulating member 20, to permit the entry, when the three-piece
pallet has been completed, of the forks utilized on the front of a
fork lift truck. It is to be understood that when the encapsulating
member has been folded around the basic pallet member 12, apertures
or openings 76 of the encapsulating member 20 move into alignment
with the apertures or openings 16, and the apertures or openings 56
of the encapsulating member move into alignment with the apertures
or openings 18 of the basic pallet member. Also visible in FIG. 1
are a pair of locking tabs 26 and 28, and a pair of locking tabs 32
and 34 that are utilized on the opposite edges of the encapsulating
member, which tabs are intended to enter and engage the elongate
slots 36 and 38 as a final step in the enclosing of the basic
pallet member 12.
[0047] In order to reveal some of the novel aspects of this
invention in greater detail, reference is now made to FIG. 2, where
it will be seen that we have depicted the novel encapsulating
member 20 in a flattened condition, with it to be noted that the
central portion 22 of this embodiment may be regarded as unbroken.
By way of example, the central portion may, for one embodiment,
measure approximately 40 inches by 40 inches, but in another
embodiment the central portion may measure 40 inches by 48 inches,
with the basic pallet member used therewith being sized
accordingly. We obviously are not to be limited to these
dimensions.
[0048] Prominently attached to the left edge of the central portion
22 as depicted in FIG. 2 is a large flap 24, attached to which are
previously-mentioned tabs 26 and 28. Attached to the right edge of
the central portion 22 is a large flap 30, attached to which are
tabs 32 and 34. As will be explained in detail hereinafter, the
pair of tabs 26 and 28, and the pair of tabs 32 and 34, play a
prominent role in securing the large flaps 24 and 30 around the
basic pallet member 12 in that those tabs are intended to enter the
earlier-mentioned slots 36 and 38 provided in the upper surface of
the basic pallet member 12, there to be retained in a locking
relationship. The resulting pallet is sturdy, and quite unlikely to
come apart in normal use.
[0049] Although it is typical for the tab-containing outermost
edges of the large flaps 24 and 30 to be disposed closely together
at such time as the basic pallet member has been encapsulated, it
is possible for somewhat smaller flaps 24 and 30 to be utilized, so
that the outermost edges are not in a touching relationship, with
the result being that centermost part of the basic pallet member 12
is not enclosed. In such an instance as this, separate
tab-receiving slots would be provided on the upper surface of the
basic pallet member, for receiving the locking tabs of the large
flaps. Understandably, the tab-receiving slots would not be
disposed on the centerline of the basic pallet member 12 in this
latter instance, but the large flaps would nevertheless encompass a
sufficient extent of the upper portion of the basic pallet member
as to create a stable and effective configuration.
[0050] Continuing with FIG. 2, it is to be understood that we
provide a number of scoring lines at the time of manufacture of the
encapsulating member 20, and for example, we may use scoring lines
40 and 42 at the base of large or major flap 24, with these
parallel scoring lines serving to define a minor flap 44. It will
be noted that rectangular openings 46 are provided, for
fork-receiving purposes, between these two scoring lines.
[0051] Similarly, we may utilize scoring lines 50 and 52 at a base
location of the large or major flap 30, with these parallel scoring
lines serving to define a minor flap 54. It will be noted that
rectangular openings 56 are disposed between these two scoring
lines. As should now be clear, the rectangular openings 46 and 56
are intended to coincide with like openings provided in the basic
pallet member, so as to make possible the entry of the forks of a
forklift truck.
[0052] In addition to the major flaps, we also prefer to utilize a
plurality of minor flaps on the encapsulating member in order to
assure the retention of the basic pallet member. It will be noted
in FIG. 2 that we provide scoring lines 60 and 62 at a location
that may be regarded as the upper portion of the encapsulating
member depicted in this figure. These parallel scoring lines serve
to define a minor flap 64 in which are located a pair of
rectangular openings 66. Similarly, we provide scoring lines 70 and
72 at a location that may be regarded as the lower portion of the
encapsulating member depicted in FIG. 2, which serve to define a
minor flap 74 in which are located a pair of rectangular openings
76. We may choose to utilize small tabs at the end of both the
minor flap 64 and the minor flap 74. As in the case of the
previously mentioned rectangular openings 46 and 56, the openings
66 and 76 are intended to coincide with like openings provided in
the basic pallet member, so as to make possible the entry of the
forks of a forklift truck.
[0053] To prevent the basic pallet member 12 from sliding out
either end of the encapsulating member 20, we prefer to use a pair
of intermediate size, almost square flaps 68 affixed to the minor
flap 64, and a pair of intermediate size, almost square flaps 78
affixed to the minor flap 74. Although this is the preferred
arrangement, it is possible in accordance with this invention to
use a single intermediate size flap in lieu of the pair of flaps
68, and a single intermediate size flap in lieu of the pair of
flaps 78. The occasion for the utilization of the intermediate size
flaps will shortly become more apparent.
[0054] Turning now to FIG. 3, it will be noted that here we
illustrate the manner in which we go about folding the flaps of the
encapsulating member 20 around the basic pallet member 12, in order
to achieve an encompassing or enclosing procedure serving to create
our novel three piece glueless pallet. It will be observed in FIG.
3 that we have already moved the intermediate size flaps 68 onto
the upper surface of one end of the basic pallet member 12, and in
a like manner, we have also moved the intermediate size flaps 78
onto the upper surface of the other end of the basic pallet member.
This having been accomplished, we are ready to start moving the
large flaps 24 and 30 onto the upper surface of the basic pallet
member. In FIG. 3 we have shown the large flap 30 having been moved
to a partial extent insofar as achieving an enclosure of the basic
pallet member 12. It will be seen in FIG. 3 that the tabs 32 and 34
are positioned so as to be ready to enter the slots 36 and 38 in
the upper surface of the basic pallet member when the large flap 30
has been brought into close contact with the upper surface of the
basic pallet member 12.
[0055] Turning to FIG. 4, it will be seen that we have here shown
the large flap 24 and the large flap 30 each having been moved into
the position in which their respective tabs are ready to enter into
a locking relationship with the aforementioned elongate slots 36
and 38 provided in the upper surface of the basic pallet member 12.
It will be noted in this figure that the rectangular openings or
apertures 76 as well as the rectangular openings or apertures 56
described in conjunction with FIG. 2 are positioned so as to permit
entry of the forks of a fork lift truck inasmuch as these openings
or apertures line up with rectangular openings or apertures
provided in the basic pallet member 12, as were depicted in FIG.
1.
[0056] With reference now to FIG. 5, it will be seen that we have
shown the encapsulating member 20 in assembled relationship with
the basic pallet member 12, but in this instance a substantial
portion of the encapsulating member 20 has been sectioned away so
as to reveal the construction permitting the entry of a pair of
forks 80 of a forklift truck. It is to be understood that the
three-piece pallet 10 is created so as to be a "four-entry pallet,"
meaning that the forks of the forklift truck can enter from any of
the four sides of the pallet.
[0057] By now it should be abundantly clear that the rectangular
openings 76 provided at one end of the encapsulating member line up
with the openings 16 provided in the basic pallet member at such
time as the basic pallet member has been enclosed; note FIGS. 1 and
3. In a like manner, the rectangular openings 56 provided in one of
the long sides of the encapsulating member line up with another set
of openings in the basic pallet member, this being openings 18. It
is thus readily possible for the forks 80 of the forklift truck to
enter a selected pair of openings, as illustrated in FIG. 5.
[0058] The tabs 26 and 28 provided on the large flap 24, and the
tabs 32 and 34 provided on the large flap 30 having entered in a
locking relationship with the elongate slots 36 and 38 provided in
the upper surface of the basic pallet member, the large flaps 24
and 30 lie flat against the upper surface of the basic pallet
member, as revealed in FIG. 5. As will thus be apparent, by
securing the encapsulating member 20 around the basic pallet member
12 in the abovedescribed manner, we have created a highly
effective, lightweight yet sturdy, three-piece pallet requiring no
glue or other securing means in its construction.
[0059] With reference now to FIG. 6, it will be seen that we have
illustrated an exemplary form of our basic pallet member 12,
considered apart from the encapsulating member. The basic pallet
member involves a lightweight component foldably constructed from a
pair of generally flat, die cut panels 14 and 15, as previously
mentioned. Although we are not to be limited to the use of any
particular material, our invention is ideally suited for the
creation of die cut panels utilizing corrugated paperboard. For
example, we may use 350 pound test, double wall corrugated
paperboard in the construction of our novel panels, but obviously
we are not to be limited to this material. Each of the pair of
panels of the basic pallet member 12 is of essentially rectangular
configuration, with each panel having ends 146 and 148 as well as
sides 152 and 154. It is to be understood that the end 146 is in a
parallel relationship with end 148.
[0060] Continuing with a consideration of FIG. 6, it has already
been mentioned that the exemplary basic pallet member we have
depicted is typically implemented in a size such as 40" by 40" or
40" by 48". In FIG. 6, the lower panel 15 as well as the upper
panel 14 of our novel basic pallet member are constructed from
corrugated paperboard that has been folded in a highly effective
manner so as to create a plurality of the previously-mentioned
longitudinally disposed structural members. In the typical
instance, a like number of longitudinally disposed structural
members is normally utilized in the creation of each of the panels
used in the construction of a given basic pallet member.
[0061] In FIG. 6 it will be noted that four longitudinally disposed
structural members, 140, 142, 144 and 150, were formed out of the
upper panel 14, and four longitudinally disposed structural
members, 160, 170, 180 and 190 were formed out of lower panel 15.
There are, however, exceptions to this, such as when, in the design
of a special purpose pallet, it may be highly desirable for one end
of the pallet to utilize a greater number of the longitudinally
disposed structural members than the other end in order that a
large, heavy, irregularly-shaped component can be adequately
supported.
[0062] It should also be pointed out that by interfitting the
longitudinally disposed structural members of one panel in a proper
angular relationship with the longitudinally disposed structural
members of the other panel, an extremely strong, grid-like
construction is created.
[0063] In the particular embodiment depicted in FIG. 6, the
previously-mentioned longitudinally disposed structural members
140, 142, 144 and 150 extend between ends 146 and 148 of the panel,
whereas the longitudinally disposed structural members 160, 170,
180 and 190 extend between side edges 152 and 154 of the panel.
[0064] It is further to be noted in FIG. 6 that an entry location
167 is defined between longitudinally disposed structural members
160 and 170, and a separate entry location 187 is defined between
structural members 180 and 190. It is into the entry location 167
that one fork 80 of a forklift truck may on occasion extend, and
into entry location 187 that the other fork 80 may at the same time
enter.
[0065] In order to permit the entry of the forks of a forklift
truck into the entry locations 167 and 187 in FIG. 6, it was
necessary in the formation of the pallet to remove certain mid
portions of the longitudinally disposed structural members 140,
142, 144 and 150.
[0066] With reference now to FIG. 7 it will be seen that we have
depicted one of the generally flat die cut panels of essentially
rectangular configuration as was used in the creation of one of the
panels of the basic pallet embodiment illustrated in FIG. 6, with
this being the lower panel 15 in this instance.
[0067] In the die cut panel depicted in FIG. 7 it will be seen that
the sides 152 and 154 are of greater dimension than the ends 146
and 148. It will be recalled that in many instances, the pallets
constructed in accordance with this invention are 40" in width and
48" in length, but obviously we are not to be limited to this. It
is pertinent to mention that if the panel depicted in FIG. 7 is to
be utilized in the creation of a pallet 48" in length, the distance
between the ends 146 and 148 of the die cut panel will be somewhat
greater than 48" inasmuch as when the distance between the ends is
caused to decrease during the folding operation utilized to bring
about the creation of the plurality of longitudinally disposed
structural members, the overall length of the panel will
necessarily decrease. In this particular instance, the panel
depicted in FIG. 7 is being used to create the lower panel 15 of
the pallet illustrated in FIGS. 1 and 6, as was previously
mentioned.
[0068] It is to be noted from FIG. 7 that we have shown four groups
or sets of scoring lines defined in spaced, parallel locations on
the panel, these being groups 160, 170, 180 and 190. From FIG. 6 it
was seen that these same numbers apply to the four longitudinally
disposed structural members created in conjunction with the lower
panel 15.
[0069] It is to be understood that the lower panel illustrated in
FIG. 7 in conjunction with a panel of identical or substantially
identical construction that has been inverted and turned 90.degree.
enables the creation of a basic pallet member of the type depicted
in FIGS. 1 and 6. It is for this reason that we find it unnecessary
to provide a separate detailed description of both the upper and
the lower panel.
[0070] It is to be seen that the scoring lines arranged in the
closely spaced parallel groups 160, 170, 180 and 190 of FIG. 7
define positions at which folding can take place when the distance
between the ends of each panel is caused to decrease. As will be
noted, group 160 is made up of scoring lines 161, 163, 164, 166;
group 170 is made up of scoring lines 171, 173, 174, 176; group 180
is made up of scoring lines 181, 183, 184 and 186; and group 190 is
made up of scoring lines 191, 193, 194 and 196. Typically the
scoring lines are created to reside in a right angle relationship
with respect to the direction of the corrugations of the
paperboard, but we are not to be limited to this.
[0071] Instead of illustrating FIG. 7 in its initial, flattened
condition, it will be noted that we have shown the panel at the
time of the commencement of the novel and highly advantageous
folding procedure utilized in accordance with this aspect of our
invention. This folding procedure serves to create the
longitudinally disposed structural members that are quite important
in the creation of our novel basic pallet members.
[0072] In FIG. 7 it will be noted with respect to the first group
of scoring lines that the central scoring lines 163-164; 173-174;
183-184; and 193-194 have started to move upwardly, out of the
plane of the panel. This upward movement of the center portions of
the scored groups is caused by the distance between the ends of the
panel starting to decrease.
[0073] This upward movement of the scored groups serves to create
in each instance, what may be regarded as a first leg between the
center scoring line and the scoring line on the left. Similarly, a
second leg is created in each group between the center scoring line
and the scoring line on the right of each group. By way of example
it will be noted in FIG. 7 that the upward movement of the center
scoring line 163 serves to create a left leg 162 between this line
and the scoring line 161, with the upward movement of the center
scoring line 164 serving to create a second or right leg 165
between the center scoring line 164 and the scoring line 166.
[0074] Similarly, the upward movement of the center scoring lines
173 and 174 serves to create a left leg 172 between line 173 and
the scoring line 171, and a second or right leg 175 between the
second center scoring line 174 and the scoring line 176.
[0075] In addition to the foregoing it will be seen that the upward
movement of the center scoring lines 183 and 184 serve to create a
left leg 182 between line 183 and the scoring line 181, and a
second or right leg 185 between the center scoring line 184 and the
scoring line 186.
[0076] Lastly it is to be noted from FIG. 7 that the upward
movement of the center scoring lines 193 and 194 serves to create a
left leg 192 between line 193 and the scoring line 191, and a
second or right leg 195 between the center scoring line 194 and the
scoring line 196.
[0077] As an option, we may in some instances prefer to secure the
right and left legs of each group together shortly after respective
right and left legs have been brought together, with such securing
being accomplished such as by the use of an adhesive, or by
mechanical fastening means.
[0078] One preferred type of mechanical fastening means will
shortly be described in some detail.
[0079] It is thus to be understood that by the time the panel ends
146 and 148 have been moved into their most inward operative
relationship, the left and right legs of each group will have been
moved into juxtaposition, thus to create the aforementioned
longitudinally disposed structural members clearly to be seen in
FIG. 6 as structural members 160, 170, 180 and 190. We prefer to
identify the upper edges of the longitudinally disposed structural
members as crests.
[0080] It is to be noted that the slots 261 through 264; slots 271
through 274; slots 281 through 284; and slots 291 through 294 are
provided for the purpose of this panel and a like panel used
thereabove to be interfitted. In the preferred instance, the
longitudinally disposed structural members of one panel are
disposed in an orthogonal relationship with the longitudinally
disposed structural members of the other panel, to form a very
strong, gridlike member. However, there may be instances in which
the longitudinally disposed structural members of one panel meet
with the longitudinally disposed structural members of the other
panel at an angle other than a right angle.
[0081] With regard to the depth of the slots, the slots provided at
spaced locations along the upper portion of the longitudinally
disposed structural members of one panel are typically of the same
depth as the slots utilized in the longitudinally disposed
structural members of the other panel. By having all of the slots
of an appropriate depth, when the panels have been interfitted
together, the crests of the series of longitudinally disposed
structural members of each panel reside in firm contact with the
undersurface of the other panel. More particularly, when the upper
and lower panels are assembled in the desired angular relationship,
the slots created in the longitudinally disposed structural members
of the upper panel interfit with the slots created in the
longitudinally disposed structural members of the lower panel.
[0082] Slots that are too shallow are undesirable, for when the
panels are interfitted, the combined height of the intersecting
longitudinally disposed structural members will be too great, and
the crests forming the tops of the longitudinally disposed
structural members of one panel will not be in contact with the
underside of the other panel. On the other hand, if the slots in
the longitudinally disposed structural members are too deep, this
serves to unnecessarily diminish the strength of the longitudinally
disposed structural members.
[0083] Although it is highly desirable for the slots, when
intersecting, to be of a depth permitting the crests of the
longitudinally disposed structural members of each panel to be in
contact with the underside of the other panel, it is possible for
the slots of one panel to be of a somewhat different depth than the
slots of the other panel, while still permitting the desired
contact of the crests of the longitudinally disposed structural
members with the underside of the other panel.
[0084] It is important to understand that quite advantageously, we
do not need to utilize glue or any other securing means between the
two panels in view of our use of the novel encapsulating member
20.
[0085] Turning now to FIG. 8, it will be seen that we have shown an
embodiment of our invention involving the preferred type of
mechanical means for securing together, the adjacent legs of the
longitudinally disposed structural members, instead of utilizing
adhesive or another means for this purpose. In FIG. 8 we use an
interlocking tab arrangement typically involving one or more
interlocking tabs on one leg of a longitudinally disposed
structural member, and corresponding tab-receiving slots on the
other leg of the structural member. The tab-receiving slots or
apertures are to be placed at locations directly opposite each
locking tab.
[0086] By referring to FIG. 9, the details of the interlocking tab
arrangement we prefer to utilize will become more apparent. For
convenience we have designated the legs of a typical longitudinally
disposed structural member to be legs L1 and L2.
[0087] As revealed in FIG. 9, we have shown a typical locking tab
or locking component to involve a generally "T" shaped component 86
located in leg L1, with it to be understood that the component 86
is to be received in a slot or opening 88 located in the opposite
leg, which is L2. Each slot 88 is of course to be placed in careful
alignment with each interlocking tab 86.
[0088] The "T" shaped component 86 is constituted by an elongate,
straight-sided portion 90, with oppositely placed wing portions 92
and 96 being attached to one end of the straight-sided portion
90.
[0089] It is important to note that a score line 100 is located at
the base of the straight-sided portion 90, and a score line 94 is
utilized between the portion 90 and the wing 92. Somewhat
similarly, a score line 98 is utilized between the portion 90 and
the wing 96.
[0090] As will be obvious to those skilled in this art, the score
lines make possible a type of hinging action between certain of
these components.
[0091] In contrast with the use of score lines, cut lines exist
along the left and right sides of the portion 90 as viewed in FIG.
9, and around the outer portions of the wing portions 92 and 96.
Also, a cut line exists across the top of the straight-sided
portion 90 as viewed in this figure. Because of this arrangement,
our "T" shaped locking tab 86 is in effect free of leg L1, except
for the hinge existing at the base location 100.
[0092] Upon the legs L1 and L2 of the longitudinally disposed
structural members being brought together, the straight-sided
portion 90 with its attached wings 92 and 96 can be pushed through
the slot 88 located in leg L2. The wings 92 and 96 fold backward
during this insertion, but afterward the wings to a large extent
return to the plane of the straight-sided portion 90; note FIG. 10
in this regard. The restoration of the wings to positions closely
corresponding to their original positions serve in a well
understood manner to secure the adjacent legs L1 and L2
together.
[0093] The leg-securing process involving the use of the
interlocking tab arrangement can be accomplished mechanically or
manually. The mechanical process calls for an arm to be positioned
such that as the necessary folds are made to form the upright legs
or longitudinally disposed structural members of a panel to be used
in the construction of the basic pallet, the arm pushes the locking
tabs through the opposing slot of the immediately adjacent leg,
thus locking the contiguous legs together. The memory recoil action
of the corrugated paperboard makes it unnecessary for any further
processes to insure a secure lock. If a manual procedure is to be
used, the same basic action takes place, with the lock tabs being
pushed through the adjacent slots with a thumb or finger.
[0094] Turning now to FIG. 11, we here depict an encapsulating
member generally along the lines of FIG. 2 but at this location
showing an embodiment of our invention that contains suitable
apertures 136 through 139, such that the completed pallet can be
used with a pallet jack.
[0095] FIG. 12 is a perspective view of the basic pallet member
generally along the lines of FIG. 6, but here indicating the use of
apertures in the lower surface of the basic pallet member that
coincide with the apertures in the encapsulating member, such that
the completed pallet can be used with a pallet jack. Note fork
members 80 of the pallet jack.
[0096] The way we preferably go about converting the prescored die
cut panels into panels in which the longitudinally disposed
structural members have been created is by the use of the machine
set forth in the Olvey et al patent application Ser. No. ______
filed in the U.S. Patent & Trademark Office on ______ and
entitled "______."
[0097] That machine involves the use of a type of table whose
planar upper surface is made up of a plurality of flat metal
members with some of these members spaced apart so as to define
longitudinally placed slots. A previously scored die cut panel that
is to be formed into a panel capable of being interfitted with a
like panel is caused to move in a precise manner across the surface
of the forming table, such as by the use of an array of endless
chains operative in the slotted locations defined between the flat
metal members forming the upper surface of the table.
* * * * *