U.S. patent application number 10/792629 was filed with the patent office on 2005-09-08 for pallet formed from molded fibrous panel material.
This patent application is currently assigned to Sonoco Development, Inc.. Invention is credited to Cassidy, Jimmy W., Jenkins, Don, Renck, Lawrence E..
Application Number | 20050193926 10/792629 |
Document ID | / |
Family ID | 34887631 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050193926 |
Kind Code |
A1 |
Cassidy, Jimmy W. ; et
al. |
September 8, 2005 |
Pallet formed from molded fibrous panel material
Abstract
A pallet is constructed of a molded fibrous panel material
comprising a sheet portion defining opposite planar surfaces, and a
grid of intersecting ribs projecting from one of the planar
surfaces of the sheet portion, the sheet portion and ribs being
integrally molded from fibrous material. The pallet comprises a
horizontal portion of the molded fibrous panel material forming an
upper support surface of the pallet, and at least two spaced
runners joined to the horizontal portion for engaging the ground to
space the horizontal portion above the ground. Each runner
comprises at least two vertical portions of the molded fibrous
panel material arranged in parallel relation and bonded to one
another. In one embodiment, a single panel member is folded along a
series of parallel fold lines extending across a width of the
member, so as to form the runners and the horizontal portion from
the single member.
Inventors: |
Cassidy, Jimmy W.;
(Hartsville, SC) ; Jenkins, Don; (Columbia,
SC) ; Renck, Lawrence E.; (Hartsville, SC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Sonoco Development, Inc.
|
Family ID: |
34887631 |
Appl. No.: |
10/792629 |
Filed: |
March 3, 2004 |
Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 2519/00323
20130101; B65D 2519/00358 20130101; B65D 2519/00019 20130101; B65D
2519/00054 20130101; B65D 2519/00268 20130101; B65D 2519/00333
20130101; B65D 19/0038 20130101; B65D 19/0026 20130101; B65D
2519/00303 20130101; B65D 2519/00412 20130101; B65D 2519/00318
20130101; B65D 2519/00407 20130101; B65D 19/0016 20130101; B65D
2519/00562 20130101; B65D 2519/00273 20130101; B65D 2519/00288
20130101; B65D 19/0048 20130101 |
Class at
Publication: |
108/051.3 |
International
Class: |
B65D 019/00 |
Claims
What is claimed is:
1. A pallet formed predominately of molded fibrous material,
comprising: a molded fibrous panel material comprising a sheet
portion defining opposite planar surfaces, and a grid of
intersecting ribs projecting from one of the planar surfaces of the
sheet portion, the sheet portion and ribs being integrally molded
in one piece from fibrous material; a horizontal portion of said
molded fibrous panel material forming an upper support surface of
the pallet; the pallet further comprising at least two spaced
runners joined to and extending downward from the horizontal
portion for engaging the ground to space the horizontal portion
above the ground, each runner comprising at least two vertical
portions of the molded fibrous panel material arranged in parallel
relation and bonded to one another.
2. The pallet of claim 1, wherein each runner includes a separate
stiffening member disposed between and bonded to two of the
vertical portions.
3. The pallet of claim 1, wherein the horizontal portion and the
vertical portions are all integrally and serially joined together
along a series of spaced parallel fold lines in the molded fibrous
panel material.
4. The pallet of claim 3, wherein each fold line comprises a groove
in the molded fibrous panel material.
5. The pallet of claim 4, wherein the grooves are molded into the
molded fibrous panel material.
6. The pallet of claim 4, wherein the grooves are formed by
mechanically removing fibrous material from the molded fibrous
panel material.
7. The pallet of claim 4, wherein at least some of the grooves are
generally V-shaped with an included angle of about 90 degrees
between opposite side walls of the groove.
8. The pallet of claim 1, further comprising a top panel affixed
atop the horizontal portion.
9. The pallet of claim 8, wherein the top panel comprises a
multi-ply laminated material.
10. The pallet of claim 9, wherein the laminated material comprises
paperboard.
11. The pallet of claim 8, wherein the top panel comprises another
piece of the molded fibrous panel material.
12. The pallet of claim 11, wherein the ribs of the top panel face
downward and the ribs of the horizontal portion face upward to
oppose the ribs of the top panel.
13. The pallet of claim 12, wherein the ribs of the top panel are
bonded directly to the ribs of the horizontal portion.
14. The pallet of claim 12, wherein the ribs of the top panel are
joined to the ribs of the horizontal portion via an intervening
piece of sheet material disposed therebetween, said sheet material
being bonded to the ribs of the top panel and horizontal
portion.
15. The pallet of claim 3, wherein the molded fibrous panel
material forming the horizontal and vertical portions comprises a
single layer of the molded fibrous panel material.
16. The pallet of claim 3, molded fibrous panel material forming
the horizontal and vertical portions comprises two layers of the
molded fibrous panel material joined rib-to-rib.
17. The pallet of claim 3, further comprising a reinforcing web
bonded to one side of the molded fibrous panel material along at
least one of the fold lines.
18. The pallet of claim 17, wherein the reinforcing web comprises a
pressure-sensitive adhesive tape.
19. The pallet of claim 3, wherein the molded fibrous panel
material has, in order, from one end to an opposite end of the
molded fibrous panel material: first, second, and third fold lines
for forming a first runner; fourth, fifth, sixth, and seventh fold
lines for forming a second runner; and eighth, ninth, and tenth
fold lines for forming a third runner.
20. The pallet of claim 1, wherein the molded fibrous panel
material is formed from recycled paper fibers.
21. The pallet of claim 20, wherein the molded fibrous panel
material is impregnated with a resin for rendering the molded
fibrous panel material substantially water-resistant.
22. The pallet of claim 1, wherein each runner comprises a first
pair of layers of the molded fibrous panel material joined
rib-to-rib.
23. The pallet of claim 22, wherein each runner comprises a second
pair of layers of the molded fibrous panel material joined
rib-to-rib and joined to the first pair such that the runner
comprises four layers.
24. The pallet of claim 22, wherein the horizontal portion
comprises a separate piece of the molded fibrous panel material
joined to the runners.
Description
FIELD OF THE INVENTION
[0001] The invention relates to pallets for supporting items during
shipment and storage. In particular, the invention relates to a
pallet formed predominately from fibrous material.
BACKGROUND OF THE INVENTION
[0002] Pallets traditionally have been manufactured of wood. The
drawbacks associated with wooden pallets are well known, as noted
for example in U.S. Pat. No. 5,184,558, incorporated herein by
reference. Briefly, such drawbacks include heaviness, which makes
the pallets cumbersome to handle and costly to ship, relatively
great expense because of the costliness of wood, and difficulty and
expense of disposing of the pallets when their useful life has been
expended.
[0003] Because of such problems, various types of non-wooden
pallets have been proposed. Some of these pallets are based on
corrugated paperboard materials; others are based on honeycomb
sandwich types of sheet materials. Still others are one-piece
structures molded from fibrous material.
[0004] Pallets based on corrugated paperboard materials suffer from
relatively poor rigidity because corrugated paperboard material by
its nature is weak in bending parallel to the running direction of
the flutes. Attempts have been made to improve rigidity in all
directions by forming laminations of multiple layers of corrugated
paperboard with the flutes in successive layers being oriented
orthogonally. There is thus a need for a substantial number of
separate pieces of corrugated sheet material, each die cut to
appropriate size and shape, the pieces then being glued together.
Thus, production and assembly of a pallet from such materials is
relatively complex and expensive.
[0005] Pallets formed from honeycomb sandwich materials likewise
tend to consist of a substantial number of separate pieces, and
hence are relatively complex and expensive to produce and assemble.
Additionally, the bond between the honeycomb cells and the face
sheets represents a weak link in honeycomb sandwich structures; if
this bond should break, the structure loses a great deal of its
bending stiffness. In honeycomb sandwich panels based on paper,
furthermore, exposure of the panels to water or other liquids can
substantially weaken the panels.
[0006] With regard to one-piece molded fibrous pallets, a
significant drawback is the need for a differently configured mold
for each different pallet size or configuration to be produced.
SUMMARY OF THE INVENTION
[0007] The invention addresses the above needs and achieves other
advantages, by providing a pallet formed of molded fibrous panel
material of a special type having substantial strength and
relatively light weight. The pallet can be constructed from a small
number of separate pieces of the panel material, or even from a
single piece of the panel material.
[0008] More particularly, in accordance with the invention, a
pallet is constructed of a molded fibrous panel material comprising
a sheet portion defining opposite planar surfaces, and a grid of
intersecting ribs projecting from one of the planar surfaces of the
sheet portion, the sheet portion and ribs being integrally molded
in one piece from fibrous material. The fibrous material can be,
for example, recycled paper fibers. If water-resistance is
required, the molded fibrous panel material can be impregnated with
a suitable resin. The panel has substantial rigidity and integrity
by virtue of its one-piece construction and the grid of
intersecting ribs.
[0009] A pallet in accordance with the invention comprises a
horizontal portion of the molded fibrous panel material forming an
upper support surface of the pallet, and at least two spaced
runners joined to and extending downward from the horizontal
portion for engaging the ground to space the horizontal portion
above the ground. Each runner comprises at least two vertical
portions of the molded fibrous panel material arranged in parallel
relation and bonded to one another.
[0010] In one embodiment, a single panel member is folded along a
series of parallel fold lines extending across a width of the
member, so as to form the runners and the horizontal portion from
the single member. Because of the substantial rigidity of the
panel, the grooves are formed in the panel to create the fold
lines. The grooves represent regions in which fibrous material that
would otherwise be there is missing or removed. The grooves
preferably are generally V-shaped with a 90-degree included angle
between opposite side walls of the grooves so that the panel can be
folded 90 degrees about the fold line. The grooves either can be
molded into the panel when it is molded, or alternatively can be
formed by mechanically removing material (e.g., by routing) from
the panel after it is formed.
[0011] In another embodiment, a top panel is affixed atop the
horizontal portion of the pallet, such as by gluing. The top panel
gives added strength to the pallet and also presents a smooth top
surface. The top panel in one embodiment comprises a laminated
multi-layer sheet, for example formed from paperboard sheets.
Alternatively, the top panel can be another piece of the molded
fibrous panel material, with the ribs facing downward toward the
horizontal portion of the pallet. The ribs of the top panel can be
bonded to the ribs of the horizontal portion, optionally with an
intervening piece of sheet material (e.g., paperboard or the like)
disposed therebetween.
[0012] The molded fibrous panel material forming the horizontal and
vertical portions of the pallet can comprise a single layer of the
molded fibrous panel material, such that one side of the panel is
planar and the other side has exposed ribs. Alternatively, the
panel material can comprise a double layer wherein the two layers
are joined rib-to-rib, for added rigidity.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0013] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0014] FIG. 1 is a perspective view of a piece of molded fibrous
panel material used for constructing pallets in accordance with the
invention;
[0015] FIG. 2 is a cross-sectional view taken along line 2-2 in
FIG. 1;
[0016] FIG. 3 is a pallet in accordance with a first embodiment of
the invention;
[0017] FIG. 4A shows a portion of a molded fibrous panel,
illustrating a series of parallel fold lines defined as V-shaped
grooves in the panel;
[0018] FIG. 4B shows the panel after being folded 90 degrees along
one of the fold lines;
[0019] FIG. 5 shows a portion of the panel of FIG. 3, depicting a
runner in greater detail;
[0020] FIG. 6 illustrates an alternative embodiment of the
invention;
[0021] FIG. 7 shows another embodiment of the invention;
[0022] FIG. 8 depicts a further embodiment of the invention;
[0023] FIG. 9 shows a still further embodiment of the invention;
and
[0024] FIG. 10 shows yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present inventions now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the invention are shown. Indeed,
these inventions may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0026] FIGS. 1 and 2 show a molded fibrous panel 20 that is used
for constructing pallets in accordance with the invention. The
panel 20 can be formed by a process generally similar to that
disclosed in U.S. Pat. No. 4,702,870 to Setterholm et al.,
incorporated herein by reference, or by a process such as described
in co-pending U.S. patent application Ser. No. ______, filed on
Dec. 5, 2003, entitled "Apparatus and Process for Forming
Three-Dimensional Fibrous Panels" incorporated herein by reference.
The process produces a three-dimensional panel that has a sheet
portion 22 defining opposite planar surfaces 24 and 26, and a grid
of intersecting ribs 28 projecting from one surface 24 of the sheet
portion. To make the panel, an aqueous fiber stock is deposited
into a mold comprising a porous support plate or screen on which
are affixed a plurality of resilient elastomeric mold pieces or
projections of truncated conical or pyramidal shape. The mold
pieces are spaced apart on the porous support plate so that
intersecting channels are defined between the mold pieces. The
aqueous stock fills the mold to a depth greater than the height of
the mold pieces, so the stock covers the upper surfaces of the mold
pieces. A flat mold plate is urged against the stock and presses
the stock down into the mold; the stock is dewatered through
openings in the porous support plate. The pressure dewaters and
densifies the panel, and the wet panel is then dried fully to
complete the process.
[0027] The panel 20 advantageously can have a thickness ranging
from about 1/4-inch to about 3/4-inch or more. The panel can be
formed from recycled paper fibers. The panel can be impregnated
with a resin to render it water-resistant, if desired. An advantage
of the panel over the prior art is its relatively large
strength-to-weight ratio, which makes possible the construction of
pallets of relatively light weight but substantial strength.
[0028] FIG. 3 depicts a pallet 30 in accordance with a first
embodiment of the invention. The pallet 30 is constructed from a
single molded fibrous panel 20 and a top panel 50. The molded
fibrous panel 20 is rectangular in shape. The panel 20 is folded
along a series of parallel fold lines to form three runners 32, 34,
36 spaced apart and parallel to one another, as further described
below. The top panel 50 is then bonded to the folded panel 20 by
gluing or the like.
[0029] The formation of the runner 32 is depicted in FIGS. 4A, 4B,
and 5; the other runners are formed in a similar fashion. The panel
20 is provided with a series of spaced, parallel fold lines A, B,
C, D, E, F, G, H, I, J (FIG. 3); the fold lines A, B, and C are
used for forming the first runner 32. The fold line A is spaced
from one edge of the panel 20 by a distance corresponding to a
desired vertical extent of the runner 32; panel section 20a is
defined between the panel edge and the fold line A. The fold line B
is spaced from the fold line A by a minimum distance roughly equal
to 1.5 to 2 times the thickness of the panel; panel section 20b is
defined between fold lines A and B. The fold line C is spaced from
the fold line B by a distance approximately equal to the vertical
height of the runner minus the thickness of the panel 20; panel
section 20c is defined between the fold lines B and C, and a panel
section 20d is connected to the panel section 20c at the fold line
C.
[0030] Because the panel 20 has substantial bending stiffness as a
result of the ribs 28, it is not possible to fold the panel without
substantial breakage of fibers and buckling of the panel along the
fold, and accordingly it is necessary to provide a groove or
channel along each of the desired lines about which the panel is to
be folded, as shown in FIG. 4A. In the region of each groove, the
ribs are substantially removed or interrupted so that the remaining
material, at least at the bottom of the groove, consists
substantially entirely of the sheet portion 22 of the panel. A
preferred configuration of the grooves is depicted in FIG. 4A. Each
groove preferably is V-shaped; the opposite side walls of the
groove preferably define an angle of substantially 90 degrees
therebetween. Accordingly, when the panel is folded 90 degrees
about the fold line, the opposite side walls of the groove come
into substantially abutting relation and can be glued together to
secure the panel in the folded position.
[0031] The V-shaped grooves can be formed in various ways. In one
embodiment, the grooves are formed during the molding process, by
suitably configuring the mold. Alternatively, the panel can be
molded without grooves, and then the panel can be routed, machined,
or otherwise mechanically operated upon to remove material to form
the grooves.
[0032] To form the runner 32, the panel sections 20a and 20b are
folded as a unit 90 degrees clockwise about the fold line B as
shown in FIG. 4B, then the panel section 20a is folded relative to
panel section 20b 90 degrees clockwise about the fold line A. At
this point, the panel sections 20a and 20c are parallel to each
other and are rib-to-rib. These panel sections are glued together
to form the runner 32. The runner is then folded 90 degrees
counterclockwise about the fold line C, with the resulting
structure being shown in FIG. 5. Panel section 20d forms a
horizontal portion of the pallet on which a load will be supported.
The other runners 34 and 36 and further horizontal portions are
similarly formed by folding the panel about the respective fold
lines D-J. Finally, the top panel 50 is attached atop the panel 20
by gluing or the like to complete the pallet construction. Although
a particular order of folding the panel 20 about the fold lines has
been described, it will be recognized that the order may be
different while arriving at the same end result.
[0033] FIG. 6 illustrates a portion of a pallet 30' in accordance
with a second embodiment of the invention. This pallet is
essentially the same as the pallet 30 described above, except that
the panel 20 is reinforced in the region of the fold lines A and B
by a reinforcing web 52. The reinforcing web 52 is employed to
prevent or minimize fiber breakage in the region of the fold lines
that may otherwise result upon folding of the panel. The
reinforcing web may be an adhesive tape such as a
pressure-sensitive adhesive tape comprising a substrate of paper or
cloth having a layer of pressure-sensitive adhesive thereon. The
reinforcing web preferably is affixed to the panel prior to
folding.
[0034] A third embodiment of the invention is depicted in FIG. 7.
The pallet 130 shown in FIG. 7 is generally similar to the pallet
30 previously described, except as noted herein. The pallet 130 has
a panel 20 folded along fold lines A, B, C, etc., so as to form
runners 32, etc., as previously described, and a top panel 50
affixed atop the panel 20. However, in the present embodiment, the
runners are reinforced with additional stiffening members. Thus,
the runner 32 is shown having a stiffening member 60 disposed
between the panel portion 20a and the panel portion 20c that make
up the runner. The stiffening member is bonded to the panel
portions 20a and 20c with adhesive or the like. To provide the
necessary space between the panel portions to accommodate the
thickness of the stiffening member 60, the fold lines A and B are
spaced slightly farther apart than in the previously described
pallet 30, so that when the panel portions 20a and 20c are parallel
to each other there is a space between them substantially equal to
the thickness of the stiffening member 60. The stiffening member 60
can comprise various materials, including but not limited to metal,
wood, hard plastic, hard rubber, fiber-reinforced plastic,
multi-layer paperboard laminations, and the like.
[0035] FIG. 8 shows a fourth embodiment of the invention. The
pallet 230 of FIG. 8 is generally similar to the pallet 30
described above, except that the top panel 250 comprises a fibrous
molded panel of the type shown in FIG. 1. Thus, the top panel 250
has a sheet portion 252 and ribs 258 projecting therefrom. The top
panel 250 is bonded to the panel 20 that forms the runners of the
pallet. Preferably, the panel 20 has its ribs 28 projecting
upwardly and the top panel 250 has its ribs 258 projecting
downwardly, and the two panels are bonded rib-to-rib. Optionally,
there can be an intervening sheet 260 of paper or other material
disposed between and bonded to the two panels.
[0036] A fifth embodiment of the invention is illustrated in FIG.
9. The pallet 330 of FIG. 9 is constructed in a fashion similar to
that used for constructing the pallet 30, except that the starting
panel 320 used for forming the runners is a double-layer panel
having two panels of the type illustrated in FIG. 1, bonded
rib-to-rib (with or without an intervening sheet therebetween).
Thus, both opposite surfaces of the panel 320 are smooth and
planar. The panel is provided with grooves along the desired fold
lines by routing or the like, as previously described, and is
folded to form the runners 332, etc., and the horizontal portions
320d, etc. However, in the pallet 330, since the horizontal
portions of the panel 320 already comprise a double-layer of panel
material, there is no need for an additional top panel. Thus, the
entire pallet is formed from one double-layer panel. As with the
embodiment of FIG. 7, the runners can be further strengthened, if
desired, by stiffening members.
[0037] Finally, a sixth embodiment of the invention is shown in
FIG. 10. The pallet 430 of FIG. 10 is formed differently from the
previously described pallets, with respect to the formation of the
runners. In this embodiment, each runner, such as the runner 432
shown in the drawing, is formed by bonding together two or more
separate and discrete pieces of panel material, and is then bonded
to a top panel of the pallet. Thus, as shown, the runner 432
comprises two double-layer pieces of panel material 440 and 442
bonded together. The piece 440 comprises two panels 440a and 440b
bonded together rib-to-rib (with or without an intervening sheet
therebetween); likewise, the piece 442 comprises two panels 442a
and 442b bonded together rib-to-rib (with or without an intervening
sheet therebetween). The pallet 430 includes a top panel 450
comprising a double-layer piece of panel material having two panels
bonded together rib-to-rib (with or without an intervening sheet
therebetween). Alternatively, the top panel could be a single layer
of the panel material, or could be another type of construction
such as a multi-layer paperboard lamination. The runners could be
formed of fewer than four layers of the panel material; for
example, the runners could comprise two layers of the panel
material. The runners could include stiffening members as
previously described.
[0038] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *