U.S. patent application number 10/509051 was filed with the patent office on 2005-07-21 for corrugated cardboard pallets.
Invention is credited to Mulcahy, Stephen, Reilly, Ian.
Application Number | 20050155527 10/509051 |
Document ID | / |
Family ID | 28676483 |
Filed Date | 2005-07-21 |
United States Patent
Application |
20050155527 |
Kind Code |
A1 |
Mulcahy, Stephen ; et
al. |
July 21, 2005 |
Corrugated cardboard pallets
Abstract
A corrugated cardboard pallet comprising a top sheet (28), a
base sheet (29) and at least one connecting member (30-38) )between
said top and said base sheets, the connecting member being moveable
to shift the pallet between a relatively flat and a relatively
erect form. Each connecting member comprises two substantially
parallel opposing main body panels (18, 20) and two pairs of
opposing side walls (X, Y) wherein each of one pair of opposing
side walls are formed from two interlocking parts (11, 14, 22,
25).
Inventors: |
Mulcahy, Stephen; (Rishton,
GB) ; Reilly, Ian; (Widnes, GB) |
Correspondence
Address: |
CHARLES N. QUINN
FOX ROTHSCHILD LLP
2000 MARKET STREET, 10TH FLOOR
PHILADELPHIA
PA
19103
US
|
Family ID: |
28676483 |
Appl. No.: |
10/509051 |
Filed: |
February 1, 2005 |
PCT Filed: |
March 10, 2003 |
PCT NO: |
PCT/GB03/01019 |
Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 19/40 20130101;
B65D 2519/00278 20130101; B65D 2519/00597 20130101; B65D 2519/00089
20130101; B65D 5/3621 20130101; B65D 2519/00029 20130101; B65D
19/0012 20130101; B65D 2519/00064 20130101; B65D 2519/0087
20130101; B65D 2519/0091 20130101; B65D 2519/00318 20130101; B65D
2519/00288 20130101; B65D 2519/00567 20130101; B65D 2519/00019
20130101; B65D 2519/00054 20130101; B65D 2519/00562 20130101; B65D
2519/00557 20130101; B65D 2519/00373 20130101; B65D 2519/0086
20130101 |
Class at
Publication: |
108/051.3 |
International
Class: |
B65D 019/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 26, 2002 |
GB |
207049.8 |
Jun 8, 2002 |
GB |
0213178.7 |
Claims
1. A corrugated cardboard pallet comprising a top sheet, a base
sheet and at least one connecting member between said top and base
sheets, the connecting member being moveable to shift the pallet
between a relatively flat and a relatively erect form characterized
in that each connecting member comprises two substantially parallel
opposing main body panels and two pairs of opposing side walls
wherein each of one pair of opposing side walls is formed from at
least two interlockable parts to enable each member to be moveable
from a flattened or collapsed state to an erect state.
2. A corrugated cardboard pallet as claimed in claim 1 wherein each
support is constructed from a blank comprising two main body
forming panels, a middle panel between said body forming panels and
at least one end flap, each main body forming panel and middle
panel having opposing side flaps, each side flap of the main body
panels being provided with an indent
3. A corrugated cardboard pallet as claimed in claim 2 wherein the
side flaps of the main body panels are secured to the side flaps of
the middle panel, the end flap is folded over the secured to the
main panel and the side flaps of the main body panels are not
secured to each other.
4. A corrugated cardboard pallet as claimed in claim 2 wherein
opposing side flaps of each main body panel are a mirror image of
one another.
5. A corrugated cardboard pallet as claimed in claim 4 wherein
adjacent side flaps of adjacent main body panels are identical.
6. A corrugated cardboard pallet as claimed in claim 5 wherein an
end flap is provided at the end of each main body forming
panel.
7. A corrugated cardboard pallet as claimed in claim 6 wherein one
of the end flaps is provided with side flaps.
8. A corrugated cardboard pallet as claimed in claim 7 wherein a
tab is provided on each of the side flaps of the main body forming
panels for attachment to side flaps of the end flap and the middle
flap in the constructed support.
9. A corrugated cardboard pallet as claimed in claim 8 wherein each
tab is provided at the remote end of the indented region of each
side flap.
10. A corrugated cardboard pallet as claimed in claim 9 wherein
fluting is formed in the longitudinal direction of the blank.
11. A corrugated cardboard panel as claimed in claim 10 wherein an
end flap of each main body forming panel is substantially the same
length as the middle panel.
12. A corrugated cardboard pallet as claimed in claim 11 wherein at
least 4 connecting members are provided between the top sheet (28)
and the base sheet (29).
13. A corrugated cardboard pallet as claimed in claim 12 wherein
between 9 and 12 members are provided between the top sheet and the
base sheet.
14. A corrugated cardboard pallet as claimed in claim 13 wherein
the connecting members are arranged at each comer of the sheets,
with at least one member positioned centrally between the comer
members along each side thereof and a further member being provided
in the centre between the sheets.
15. A corrugated cardboard pallet as claimed in claim 14 wherein
the central connecting member is the largest size of member and the
members provided at the corners are the smallest in size.
16. A corrugated cardboard pallet as claimed in claim 15 wherein
the base sheet is provided with regions that are relieved of
material to provide access points from below the pallet.
17. A corrugated cardboard pallet as claimed in claim 16 wherein
the base sheet, top sheet and at least one connecting member are
all secured together by means of adhesive only.
18. A corrugated cardboard pallet as claimed in claim 17 wherein a
varnish is applied to the top sheet, base sheet and/or at least one
connecting member.
19. A corrugated cardboard pallet as claimed in claim 18 wherein at
least one additional sheet is secured to the top and/or base
sheet.
20. A corrugated cardboard pallet as claimed in claim 19 wherein
the additional sheet is a cross ply board.
21. A corrugated car(board pallet as claimed in claim 20 wherein
fluting of the additional sheet lies at 90 degrees to the direction
of fluting on the sheet to which it is applied.
22. A method of manufacturing a corrugated cardboard pallet
comprising the steps of passing a top sheet along a conveyor,
feeding at least one connecting member on to the top sheet and
securing a base sheet to the connecting member, characterized in
that the connecting member is moveable between a flattened and an
erect state and is applied to the top sheet in its flattened
state.
23. A method as claimed in claim 22 wherein adhesive is applied to
the connecting member prior to feeding it on to the top sheet.
24. A method as claimed in claim 25 wherein a plurality of
connecting members are fed onto different locations on the top
sheet.
25. A method as claimed in claim 24 wherein the connecting members
are fed from hoppers.
Description
DESCRIPTION
[0001] The present invention relates to improvements in corrugated
cardboard pallets.
[0002] Pallets are in everyday use and are usually made from wood,
polythene, plastic or metal. The pallets may be of a general size,
such as those used in the retail and retail goods manufacturing
industries, or they may be made for specific applications. Their
chief purpose is to safely store goods or product in quantity and
allow the goods or product to be mechanically handled within
manufacturing units. The pallets also act as shipping units, often
via vehicle transport, to the retail outlet. Again, at the retail
outlet the pallets are mechanically handled and stored prior to
transport to individual stores. The pallet may then be used to
display the goods or product directly on the shop floor, as a form
of merchandising unit.
[0003] Pallets are normally of a high initial cost and there are
systems of pallet hire in place. Pallets may also be purchased
second hand, but are again costly, and may be prone to
contaminants. They are bulky and are normally of a standard height
and size so that both the manufacturer and retailer storage systems
are compatible. Wooden pallets are heavy to manhandle and add to
the crush weight of stored and transported goods or product because
often several pallets of goods or product are stored on top of one
another. A standard wooden pallet typically weighs between 25 Kg
and 50 Kg. This means that manhandling is difficult and the weight
can damage the goods or product that the pallet rests upon. This
type of pallet is also costly to transport because of its inherent
weight.
[0004] A typical operation of a re-usable pallet may be as follows.
Manufactured product such as boxed dry goods are collated and
stacked on to a standard wooden pallet. A man may then place a
pallet on top of this stacked pallet and proceed to collate and
place more boxed product on top of this. Depending upon how many
layers of product are used on each pallet, each single stack may
contain several pallets. The stack is then normally enshrouded in
stretch wrap to form a unit that is then mechanically handled by a
manual pump truck or a mechanical fork lift truck and placed into
storage. After a period of time, the product is ordered by a
retailer and the unit is mechanically loaded onto a transport
vehicle. At the retailer's depot, the unit is unloaded and stored
for a further period. It is then loaded onto another vehicle and
delivered into a retail shop, where it may be stored or placed
direct for merchandising onto the shop floor.
[0005] The problem with the aforementioned operation is that the
manufacturer does not get the pallet back. This is very costly to
the manufacturer and, ultimately, the consumer. After the product
or goods are used from the pallet, the retailer must then dispose
of the wooden pallet, which is bulky and heavy. The disposal of the
pallet requires expensive transport and is costly to the
environment since most pallets end up in landfill. It is estimated
that there are around 5 wooden pallets in existence for each person
in the British Isles.
[0006] If a hire system is used, a pallet must be hired by a
manufacturer. A system of tracking the pallets is required which is
both labour intensive and costly. The pallet is then left with the
retailer. The retailer may have a stock of empty pallets which he
can give back to the manufacturer, requiring the loading of a
vehicle to transport bulky, heavy and empty pallets back to the
manufacturer at his own cost. A manufacturer also has to pay to
de-hire a pallet and, if one is lost, will have to pay full cost
for it. The returned pallets can be hired out again in a repeat
cycle. Re-using pallets also leads to problems of cleanliness and
repair. Wooden pallets are normally put together with nails which
may become exposed and damage the goods or product placed upon
them. Furthermore, wooden pallets may produce large or small
splinters that can either damage the product or even enter and
contaminate the product, especially food goods.
[0007] The standard height of most pallets, usually being about 160
mm, dictates how much product can be transported on a vehicle, such
as a curtain slider. Wooden pallets are heavy and may double in
weight when wet, making manual handling dangerous.
[0008] It is an object of the present invention to provide an
improved corrugated cardboard pallet, that aims to overcome, or at
least alleviate the abovementioned drawbacks.
[0009] It is a further object of the present invention to provide a
method of manufacture for the production of a corrugated cardboard
pallet.
[0010] Accordingly, a first aspect of the present invention
provides a corrugated cardboard pallet, the pallet comprising a top
sheet, a base sheet and at least one connecting member between said
top and said base sheets, the connecting member being moveable to
shift the pallet between a relatively flat and a relatively erect
form.
[0011] The provision of a pallet that may be adjusted from a flat
to an erect form is preferably provided by means of a number of
connecting members being secured between the top sheet and the base
sheet. Each member is constructed such as to be moveable from a
flattened or collapsed state to an erect state. More preferably,
each connecting member is in the form of a corrugated cardboard
support comprising two substantially parallel opposing main body
panels and two pairs of opposing side walls wherein each of one
pair of opposing side walls are formed from two interlocking
parts.
[0012] The provision of a pair of opposing side walls that are each
comprised of two interlocking parts enables the assembled support
to be moveable from a collapsed state to an erect state. In the
collapsed or flattened state, two parts of each wall are disengaged
to allow each part to lie flat against its connecting wall or
panel. In the erect state, the two parts of each wall become
interlocked and lie substantially perpendicularly to their
connecting wall or panel.
[0013] Preferably, a corrugated cardboard blank is provided for the
construction of each support, the blank comprising two main body
forming panels, a middle panel between said body forming panels and
at least one end flap, each main body forming panel and middle
panel having opposing side flaps, each side flap of the main body
panels being provided with an indent.
[0014] It is to be appreciated that a support is assembled from the
blank by folding the appropriate parts of the blank and securing
them together using suitable means, most preferably an adhesive.
The side flaps of the main panels are secured to the side flaps of
the middle panel and the end flap is folded over and secured to the
main panel. However, the side flaps of the main body panels are not
secured to each other.
[0015] The provision of an indent in each side flap of each main
body forming panel enables a side flap of one main body panel to
engage with the adjacent side flap of the other main body panel
when the blank is assembled to form an erect box, thereby forming a
double blind box. Prior to engagement of the flaps, the box is in a
flattened state. This enables the blank to be assembled into a box
that may take on a collapsed or an erect state.
[0016] Opposing side flaps of each main body panel are preferably a
mirror image of one another. Adjacent side flaps of adjacent main
body panels are preferably identical.
[0017] Preferably, an end flap is provided at the end of each main
body forming panel. More preferably, one of the end flaps is also
provided with side flaps. A tab is preferably provided on each of
the side flaps of the main body panels for attachment to the side
flaps of the end flap and middle panel in the constructed box.
[0018] Each tab is preferably provided at the remote end of the
indented region of each side flap. Preferably, a line of weakness
is provided between each tab and its adjoining side flap.
[0019] Each side flap of the main body forming panels, middle panel
and/or end flap is preferably provided with one corner that forms
substantially a right angle and an opposing corner which is
truncated. Each tabe provided on the side flaps of the main body
forming panels preferably extends from the truncated end of the
side flap.
[0020] It is preferable for fluting to be formed in the
longitudinal direction of the blank, i.e. from one end flap to the
other since this increases the strength of the box formed from the
blank and thereby imparts strength to the pallet.
[0021] The main panels and walls of the support may be any desired
size.
[0022] Preferably, at least four supports as hereinbefore described
are provided between the top and base sheet to form the pallet,
optionally being of different sizes. More preferably, between nine
and twelve supports are provided but the exact number will depend
upon the size of the pallet and on the size of the supports and
hence, any number may be provided as desired.
[0023] The supports are arranged so as to provide a stable pallet
in its erect form and so that there are gaps between adjacent
supports to provide side access points to the pallet. Supports may
be provided at each corner of the sheets, with a support positioned
centrally between the corner supports along each side thereof and a
further support being provided in the centre between the sheets.
Preferably, the support provided in the centre is the largest size
of support and the supports provided at the corners are the
smallest in size.
[0024] The base sheet is preferably provided with regions that are
relieved of material to provide access points from below the
pallet. Preferably, two to four rectangular areas are relieved of
material. However, any suitable number of access points may be
provided in the pallet, being formed through the base sheet and/or
by the spacing between adjacent supports provided between the
sheets of the pallet.
[0025] In a preferred embodiment of the present invention, the
components of the pallet are secured together by means of adhesive
only. A varnish may be applied to the top sheet, base sheet and/or
supports to impart water resistance.
[0026] Additionally, at least one further sheet, for example a
cross ply board, may be laminated to the top and/or base sheet to
increase the strength of the pallet. Preferably, the fluting of the
additional sheet lies at 90 degrees to the direction of fluting on
the sheet to which it is applied.
[0027] A fourth aspect of the present invention provides a method
of manufacturing a corrugated cardboard pallet comprising the steps
of passing a top sheet along a conveyor, feeding at least one
connecting member on to the top sheet and securing a base sheet to
the connecting member.
[0028] Preferably, an adhesive is applied to the connecting member
prior to feeding it on to the top sheet. Preferably, the connecting
member is moveable between a flattened and erect state and is
applied to the top sheet in its flattened state.
[0029] Generally, a plurality of connecting members will be fed
onto different locations on the top sheet. Preferably, the
different connecting members are fed from hoppers.
[0030] For a better understanding of the present invention and to
show more clearly how it may be carried into effect reference will
now be made, by way of example only, to the accompanying drawings
in which:
[0031] FIG. 1 is a plan view of a blank for a double-blind box
according to one embodiment of the present invention;
[0032] FIG. 2 is a perspective view of an erect double-blind box
according to the present invention assembled from the blank shown
in FIG. 1;
[0033] FIG. 3 is a perspective view of a double-blind box shown in
FIG. 2, shown in its collapsed form;
[0034] FIG. 4 is a plan view of a top part for a pallet according
to one embodiment of the present invention;
[0035] FIG. 5 is a plan view of the base part for a pallet
according to one embodiment of the present invention;
[0036] FIG. 6 is a perspective view of an assembled pallet
according to one embodiment of the present invention utilising the
parts shown in FIGS. 1 to 3, 4 and 5;
[0037] FIG. 7 is a view of the underside of the top part of the
pallet showing the location of the double-blind boxes;
[0038] FIG. 8 is a schematic plan view of an apparatus for the
assembly of a pallet according to one embodiment of the present
invention; and
[0039] FIG. 9 is a schematic perspective view of the apparatus
shown in FIG. 8 illustrating the feed of one type of double-blind
box from a hopper.
[0040] Referring to FIG. 1 of the accompanying drawings, a plan
view of a blank 2 for the construction of a double-blind box for
forming a support for use in a pallet according to one embodiment
of the present invention is illustrated. The blank is cut from a
sheet of corrugated cardboard and creases are inserted into the
blank to provide fold lines, represented by broken lines in FIG. 1.
Heavy dotted lines denote reverse fold lines. The blank has two
main body forming panels 18, 20 connected by a middle section 19.
The two main body forming panels 18, 20 are provided with end
sections 17, 21 respectively opposite said middle section 19. Each
main body panel has side flaps 11, 22, 14, 25 extending from each
side thereof, each side flap having an indent I. One end of each
flap is straight and the other opposing end nearest the indent is
oblique. Each oblique end is provided with a tab 12, 23, 15, 26.
The middle section 19 is also provided with side flaps 13, 24, one
end being straight and the other being oblique. Similar side flaps
16, 27 are provided extending from one end section 21 but the
opposing end section 17 is free from flaps.
[0041] The blank may be assembled to form a support 10 for a
pallet, the support comprising two substantially parallel opposing
main body panels (18, 20) and two pairs of opposing side walls (X,
Y) wherein each of one pair of the opposing side walls (Y) are
formed from two interconnecting parts (11, 14 and 22, 25) to enable
the support to be moveable from a collapsed state to an erect
state, as shown in FIGS. 2 and 3.
[0042] To form the box 10, side flaps 11, 22 are folded flat on to
the main body forming panel 18 and the tabs 12, 23 are folded back
to lie against the side flaps. Glue is then applied to the tabs 12,
23. The side flaps 12, 24 are then folded against the middle
section 19. The main body forming panel 18 is then folded against
the middle section 19 so that the tabs 12, 23 adhere to their
adjacent side flap 23, 24. Side flaps 14, 25 are then folded on to
the other main body forming panel 20 and the tabs 15, 26 are folded
back to lie against the side flaps 14, 25. Glue is then applied to
these tabs and the side flaps 16, 27 are folded flat against the
end section 21. The end section 21 is now folded against the main
body forming panel 20 so that the side flaps 16, 27 adhere to their
adjacent tab 15, 26 respectively. Finally, glue is applied to the
opposing end section 17 which is placed over to stick to the outer
surface of the other end section 21 to form an assembled box 10, as
shown in FIG. 2. The construction of the box from a blank may be
achieved using multi-point machine gluers at high speed.
[0043] As mentioned above, the construction of the box 10 is such
that it may be provided in a collapsed form (FIG. 3) or an erect
form (FIG. 2). Assembly of the box into its collapsed form requires
the side flaps 11, 14, 22, 25 of the main body forming panels to be
pressed inwardly such that they lie against their respective panel.
Pushing inwardly the outer surface of the collapsed box, in
particular the middle section 19 and end section 17, forces the
side flaps away from their panel and the flaps lock together by
means of the indent I. This forms a double blind box that is
extremely difficult to re-collapse.
[0044] It has been found that the provision of fluting in the
longitudinal direction C, shown in FIG. 1, provides for a much
stronger box thus enabling the box to support greater weights. This
is opposite to the direction of fluting provided in conventional
corrugated cardboard boxes.
[0045] The direction of fluting and the provision of two blind ends
in the box results in the erected box being inherently strong.
Prior hereto one end of a box would be openable to enable items to
be placed within the box. The box according to the present
invention may be used as a support, for example acting as a display
shelf to support goods that are for sale. The box has advantages
over the prior art supports, such as its ability to be transported
and stored flat until required and its ability to be recycled. It
is also made of cheap materials.
[0046] A preferred application for a box according to the present
invention is the construction of a pallet wherein a plurality of
boxes are adhered to a top and bottom sheet to provide a pallet
that is moveable from a collapsed to an erect state. Any required
size of pallet may be provided and the larger the pallet, generally
the more boxes that will be used in its construction.
[0047] FIGS. 4 to 7 of the accompanying drawings illustrate one
pallet according to the present invention. This embodiment is made
from eleven single sheets of corrugated cardboard, which are
stamped out as shown in FIG. 1, FIG. 4 and FIG. 5. A solid
rectangular sheet 28 is provided to form the top of the pallet and
a further rectangular sheet 29 of substantially the same size is
provided for forming the base of the pallet, this sheet having two
rectangular sections 40, 42 that are relieved of material.
[0048] Nine boxes 30-38 according to the present invention are
glued in their collapsed form to the underside of the top sheet 28,
as shown in FIG. 7. This figure details the location of the nine
double blind boxes that create the compressive strength of the
pallet. In the embodiment shown, there are four different sizes of
box for each pallet. A smallest size of box 30, 32, 36, 38 is
placed at each corner of the sheet. A largest box 34 is placed in
the centre of the pallet. Another size of box 31, 37 is positioned
centrally along two opposing faces of the pallet between the corner
boxes and yet a further size of box 33, 35 is placed centrally
along the other two opposing faces of the pallet. Glue is then
applied to the panel 20 of the boxes and the bottom sheet 29 of the
pallet is then stuck onto the flattened boxes.
[0049] It is to be appreciated that any number of boxes may be used
to form the pallet. The boxes may be of an identical size of may be
different size.
[0050] The pallet may be erected by striking an edge of the pallet
on the floor, or by way of machine, causing each of the boxes to
move into their erect form thereby popping the pallet into its
extended state. FIG. 6 of the accompanying drawings illustrates the
pallet in its extended state.
[0051] The orientation of the fluting on the top sheet may be any
direction but the orientation of the fluting with respect of the
boxes is important to provide overall compressive strength of the
pallet. The positioning of the boxes is such as to provide access
for a mechanical forklift along all four edges of the pallet. The
boxes are also positioned so that they will always be in the
correct position to bear on standard warehouse racking systems. The
mechanical handling forks can be introduced at A or B on either
edge of the pallet, as illustrated in FIG. 6. If a pallet truck is
used for handling, then the wheels roll over the pallet base 29 and
then sit against the floor as the pallet is elevated for
moving.
[0052] An additional sheet (not shown), for example of cross ply
board, may be secured to the top and/or base sheet to increase the
strength of the pallet. The fluting of the additional sheet is
preferably transverse to the direction of fluting on the sheet to
which it is applied.
[0053] FIGS. 8 and 9 of the accompanying drawings illustrate one
embodiment of an apparatus for the automatic construction of
pallets according to the present invention. In the embodiment
shown, a pallet is manufactured from eleven pieces of corrugated
cardboard that have been stamped out. A top sheet 28 is fed onto a
conveyor 100. The top sheet of the pallet may be made from a
plurality of walled corrugated cardboard, depending upon the
strength characteristics required. It is envisaged that a pallet
will normally be used with loads of less than 700 Kg but by varying
the grammage of the board used, and the type of fluting, it can be
made to withstand considerably more weight.
[0054] Nine collapsible boxes 10 are fed from hoppers 101-104 on to
the top sheet. The hoppers are located such that the boxes are
positioned in their correct position on the sheet 28. Each
flattened box is passed over glue applicator wheel 112 housed
within a glue bath 110 and is applied to the underside of the top
sheet by means of an applicator wheel 114. A bottom sheet 29 is
then fed onto the top of the boxes 10 from a sheet feeder 106 to
form a collapsed pallet. The bottom sheet is also of corrugated
cardboard having access slots cut into it so the assembled article
can be mechanically handled by a pump truck.
[0055] The boxes 10 give the pallet its load bearing capability.
The boxes are unique double blind boxes with self-erecting ends, as
described in FIGS. 2 and 3. When the sides of the box are pressed
inwardly, they form a rigid box that cannot be flattened again. The
boxes also have a degree of flexibility so that vibrating movement
through them will have a dampened action. No metal staples are
used, just glue. When the pallet is un-erected in flat form, the
preferred embodiment is only about 25 mm thick. In contrast, when
the edges are struck on a surface, or pushed together, the pallet
pops into a rigid 100 mm high pallet. The pallet may be machine
erected, as in conventional automated palletising systems, or may
be easily hand erected in one motion by striking one edge on the
floor.
[0056] The absence of any metal mechanical fastenings means that
the pallet cannot damage or contaminate any product or goods placed
therein. Its reduced height vis--vis the conventional type of
pallet means that extra product layers may be gained for transport.
The cardboard may also be treated with varnish or other suitable
means to make it water resistant and may be printed with
descriptors or other decoration, such as in for use in a shop
display merchandising unit.
[0057] The provision of pallets made from corrugated cardboard that
are moveable between a collapsed and erect form overcomes many of
the difficulties associated with the prior art type of pallets. The
pallet may be stored in its flat form, thus potentially giving a
600% saving on storage space over the conventional pallet systems.
Transportation prior to use can also be done with the pallet in its
flattened form, meaning that fewer vehicles are needed. For
example, it is envisaged that 4000 of the pallets according to the
present invention will be able to be transported by a single
vehicle whereas 11 vehicles would be required to transport the same
number of conventional wooden pallets. Thus, a pallet according to
the present invention has clear economical and environmental
benefits. Furthermore, once erected, a pallet according to the
present invention may only be about 100 mm high, being almost half
the height of a standard wooden pallet but tall enough to enable
handling by all standard mechanical means. The pallet according to
the present invention is designed for single trip use. Whilst the
pallet is robust enough to be mechanically handled and transported
several times, it is envisaged that the pallet will be compacted
after use and recycled. In this respect, the pallet is 100%
recyclable. This saves on storage space and costly return
transport. Furthermore, the pallet is far cheaper to make than
other types of wooden pallet currently in existence, minimising the
cost to the ultimate consumer.
[0058] On average, a pallet according to a preferred embodiment of
the present invention weighs about 1-3 Kg. In contrast, a
conventional wooden pallet weighs between 25-50 Kg. Thus, the
present pallet can be manually handled without any worry of health
and safety weight constraints. Its lightness also assists in the
prevention of product damage when the pallet is used in
multi-stacked units. It is designed for two-way or four-way entry
and can be handled by a manual pallet pump truck or various
mechnical forklift trucks without modification. The pallet is also
designed so that it can be placed safely in the majority of racking
systems.
[0059] A further benefit provided by a pallet according to the
present invention is that its basic constructional design can be
used to provide any size of pallet required. By varying the grade
of corrugated cardboard used, the box or pallet can be made to
withstand varying dead loads up to several tons.
[0060] Additionally, the provision of a pallet that is intended for
a single use reduces the risk of any contamination of the product
from the pallet. Wooden pallets require fumigation against wood
boring insects. The single use aspect of the pallet also reduces
incidental costs associated with the provision of manpower to
control the pallets, clean the pallets and store and unload the
pallets.
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