U.S. patent application number 11/070298 was filed with the patent office on 2005-10-20 for hybrid shipping pallet system.
Invention is credited to Aden, Alan, Hollander, David S..
Application Number | 20050229819 11/070298 |
Document ID | / |
Family ID | 35094943 |
Filed Date | 2005-10-20 |
United States Patent
Application |
20050229819 |
Kind Code |
A1 |
Hollander, David S. ; et
al. |
October 20, 2005 |
Hybrid shipping pallet system
Abstract
A shipping pallet includes a deck having an upper surface and an
opposing lower surface and a plurality of deck support structures,
each of the deck support structures having a plurality of prongs
protruding from an upper surface thereof. The plurality of prongs
of each deck support structure penetrate and engage the lower
surface of the deck so as to cause the plurality of deck support
structures to be attached to the deck.
Inventors: |
Hollander, David S.;
(Brooklyn, NY) ; Aden, Alan; (Longwood,
FL) |
Correspondence
Address: |
ST. ONGE STEWARD JOHNSTON & REENS, LLC
986 BEDFORD STREET
STAMFORD
CT
06905-5619
US
|
Family ID: |
35094943 |
Appl. No.: |
11/070298 |
Filed: |
March 2, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60549842 |
Mar 3, 2004 |
|
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Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 19/0026 20130101;
B65D 2519/00069 20130101; B65D 2519/00567 20130101; B65D 2519/00333
20130101; B65D 2519/0098 20130101; B65D 2519/00323 20130101; B65D
2519/00019 20130101; B65D 2519/00288 20130101; B65D 2519/00273
20130101; B65D 2519/00825 20130101 |
Class at
Publication: |
108/051.3 |
International
Class: |
B65D 019/00 |
Claims
What is claimed is:
1. A shipping pallet comprising: a deck having an upper surface and
an opposing lower surface; a plurality of deck support structures,
each of said deck support structures having a plurality of prongs
protruding from an upper surface thereof; and wherein the plurality
of prongs of each deck support structure penetrate and engage the
lower surface of said deck so as to cause the plurality of deck
support structures to be attached to said deck.
2. The shipping pallet of claim 1 wherein said deck comprises
corrugated board having at least one intermediate corrugated member
sandwiched between linerboard facings.
3. The shipping pallet of claim 2 wherein said deck comprises
triple wall corrugated board having three intermediate corrugated
members sandwiched between four linerboard facings.
4. The shipping pallet of claim 2 wherein the intermediate
corrugated members and the linerboard facings are treated
internally for water resistance using a waterproofing chemical
treatment or sizing, whereby the shipping pallet is water
resistant.
5. The shipping pallet of claim 4 wherein the linerboard facings
are coated with a waterproof coating, whereby the shipping pallet
is waterproof.
6. The shipping pallet of claim 1 wherein said deck comprises a
Kraft paper honeycomb panel having a honeycomb core sandwiched
between linerboard facings.
7. The shipping pallet of claim 6 wherein the honeycomb core and
the linerboard facings are treated internally for water resistance
using a waterproofing chemical treatment or sizing, whereby the
shipping pallet is water resistant.
8. The shipping pallet of claim 7 wherein the linerboard facings
are coated with a waterproof coating, whereby the shipping pallet
is waterproof.
9. The shipping pallet of claim 1 wherein each of said plurality of
deck support structures comprises a unitized extruded or molded
part formed from a plastic material.
10. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures comprises at least one of structural
foam polypropylene and structural foam polyethylene.
11. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures is formed from a recycled plastic
material.
12. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures is formed from a virgin plastic
material.
13. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures comprises three post sections set
between a lower skid and an upper rail.
14. The shipping pallet of claim 13 wherein the plurality of prongs
of each deck support structure, protrude from an upper surface of
the upper rail.
15. The shipping pallet of claim 1 wherein each of the plurality of
prongs comprises a barb so as to enhance attachment between said
plurality of deck support structures and said deck.
16. The shipping pallet of claim 15 wherein the barb is formed in a
substantially vertical surface of each of the plurality of
prongs.
17. The shipping pallet of claim 16 wherein each of the plurality
of prongs further comprises a sloped surface, and wherein the barb
is positioned on a side of the prong opposite to the sloped
surface.
18. The shipping pallet of claim 15 wherein the barb is formed in a
sloped surface of each of the plurality of prongs.
19. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures is attachable without tools to said deck
by forcing each of said plurality of deck support structures and
said deck together such that the plurality of prongs of each deck
support structure penetrate and engage the lower surface of said
deck.
20. The shipping pallet of claim 1 wherein each of said plurality
of deck support structures is detachable without tools from said
deck by gripping an end of each of said plurality of deck support
structures adjacent an end thereof and pulling each of said
plurality of deck support structures away from said deck.
21. A shipping pallet comprising: a deck having an upper surface
and an opposing lower surface, said deck comprising corrugated
board having at least one intermediate corrugated member sandwiched
between linerboard facings; a plurality of deck support structures,
each of which comprises a unitized extruded or molded part formed
from a plastic material, each of said deck support structures
having a plurality of prongs protruding from an upper surface
thereof; wherein the plurality of prongs of each deck support
structure penetrate and engage the lower surface of said deck so as
to cause the plurality of deck support structures to be attached to
said deck; wherein each of the plurality of prongs comprises a barb
so as to enhance attachment between said plurality of deck support
structures and said deck; wherein each of said plurality of deck
support structures is attachable without tools to said deck by
forcing each of said plurality of deck support structures and said
deck together such that the plurality of prongs of each deck
support structure penetrate and engage the lower surface of said
deck; and wherein each of said plurality of deck support structures
is detachable without tools from said deck by gripping an end of
each of said plurality of deck support structures adjacent an end
thereof and pulling each of said plurality of deck support
structures away from said deck.
22. The shipping pallet of claim 21 wherein said deck comprises
triple wall corrugated board having three intermediate corrugated
members sandwiched between four linerboard facings.
23. The shipping pallet of claim 21 wherein the at least one
intermediate corrugated member and the linerboard facings are
treated internally for water resistance using a waterproofing
chemical treatment or sizing, whereby the shipping pallet is water
resistant.
24. The shipping pallet of claim 23 wherein the linerboard facings
are coated with a waterproof coating, whereby the shipping pallet
is waterproof.
25. The shipping pallet of claim 21 wherein each of said plurality
of deck support structures comprises at least one of structural
foam polypropylene and structural foam polyethylene.
26. The shipping pallet of claim 21 wherein each of said plurality
of deck support structures comprises three post sections set
between a lower skid and an upper rail.
27. The shipping pallet of claim 26 wherein the plurality of prongs
of each deck support structure protrude from an upper surface of
the upper rail.
28. The shipping pallet of claim 21 wherein the barb is formed in a
substantially vertical surface of each of the plurality of
prongs.
29. The shipping pallet of claim 28 wherein each of the plurality
of prongs further comprises a sloped surface, and wherein the barb
is positioned on a side of the prong opposite to the sloped
surface.
30. The shipping pallet of claim 21 wherein the barb is formed in a
sloped surface of each of the plurality of prongs.
31. A shipping pallet comprising: a deck having an upper surface
and an opposing lower surface, said deck comprising triple wall
corrugated board having three intermediate corrugated members
sandwiched between four linerboard facings; a plurality of deck
support structures, each of which comprises a unitized extruded or
molded part formed from at least one of structural foam
polypropylene and structural foam polyethylene, each of said deck
support structures comprising three post sections set between a
lower skid and an upper rail, and having a plurality of prongs
protruding from an upper surface of the upper rail; wherein the
plurality of prongs of each deck support structure penetrate and
engage the lower surface of said deck so as to cause the plurality
of deck support structures to be attached to said deck; wherein
each of the plurality of prongs comprises a barb so as to enhance
attachment between said plurality of deck support structures and
said deck, the barb being formed in a substantially vertical
surface of each of the plurality of prongs, which substantially
vertical surface is positioned opposite to a sloped surface of the
barb; wherein each of said plurality of deck support structures is
attachable without tools to said deck by forcing each of said
plurality of deck support structures and said deck together such
that the plurality of prongs of each deck support structure
penetrate and engage the lower surface of said deck; and wherein
each of said plurality of deck support structures is detachable
without tools from said deck by gripping an end of each of said
plurality of deck support structures adjacent an end thereof and
pulling each of said plurality of deck support structures away from
said deck.
32. The shipping pallet of claim 31 wherein the intermediate
corrugated members and the linerboard facings are treated
internally for water resistance using a waterproofing chemical
treatment or sizing, whereby the shipping pallet is water
resistant.
33. The shipping pallet of claim 32 wherein the linerboard facings
are coated with a waterproof coating, whereby the shipping pallet
is waterproof.
Description
RELATED APPLICATIONS
[0001] This patent application claims the benefit of, under Title
35, United States Code, Section 119(e), U.S. Provisional Patent
Application No. 60/549,842, filed Mar. 3, 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to an improved pallet for
packaging, material handling, shipping, and the like. More
particularly, the present invention relates to a hybrid shipping
pallet system that has numerous advantages over currently known
wood, plastic and paper pallets.
BACKGROUND OF THE INVENTION
[0003] Traditionally, pallets have been made of wood planks nailed
together. In one common structure, a series of parallel upper wood
planks are nailed to the top of three transversely extending,
parallel, and equally-spaced wood support planks. Similarly, a
series of parallel lower wood planks are nailed to the bottom of
the three support planks. The tines of forklifts and/or pallet
jacks can slide under the upper planks in the two parallel channels
formed by the three spaced support planks. The forklift or pallet
jack can then raise its tines, which lifts the pallet and anything
mounted on it. While such pallets have been used for decades, they
suffer from a surprising number of deficiencies.
[0004] Outbreaks of non-indigenous insect pests (such as the Asian
long horn beetle and the pinewood nematode) across continents have
been traced in part to wood transport packaging, including wood
pallets. Within the past year, it was reported that Asian long horn
beetles had invaded and now threatened to destroy the maple tree
population of Central Park in New York City. The first organized
effort to combat this emerging crisis began when on Oct. 1, 2001,
in an effort to stop infestation by the pinewood nematode, the
European Union imposed short term "emergency measures" on all
coniferous (softwoods, such as pine) solid wood packaging
originating in the U.S., Canada, China, and Japan. Strict
enforcement was scheduled to begin after Oct. 1, 2002, with severe
consequences for non-compliance.
[0005] With insect infestations posing a serious and imminent
threat to plant and tree health worldwide, these short-term
emergency measures have now been superceded by global standards
developed by the International Plant Protection Organization
(IPPO), a division of the United Nations. In March 2002,
representatives from almost ninety nations officially passed these
new global standards. These global standards require all solid wood
packaging--both hardwood and softwood--to be heat treated at
56.degree. C. for 30 minutes, and stamped to certify compliance. In
addition to heat treatment, other treatment methods authorized
under the standards include: kiln drying, chemical pressure
impregnation, and fumigation. Implementation of these global
standards will be left up to each member country. While it is
anticipated that it could take 1-2 years to implement the standard,
some European nations and Canada had put this standard in place by
the end of 2002 because of the spreading pinewood nimetode
threat.
[0006] These requirements for the treatment of wood pallets have
made the use of such wood pallets disadvantageous for many reasons,
including increased cost and manufacturing complexity. However, it
should be noted that since plastics and paper/corrugated packaging
materials are inherently bug-proof, these new regulations apply
only to international shipments involving wood packaging materials.
Upon inspection for export, any wood pallet found not to be in
compliance with the rules would be destroyed, forcing goods to be
re-palletized onto an approved pallet, or fumigated on site--all at
the expense of the shipper.
[0007] Another deficiency of wood pallets relates to environmental
concerns. According to the Rainforest Action Network, an
environmental group, more than one million forest acres are chopped
every year for wood pallets. The very title and by-line of an
Article that appeared in the Wall Street Journal in 1998, cogently
captures the essence of the environmental concerns about wood
pallets: "As Old Pallets Pile Up, Critics Hammer Them As a New
Eco-Menace", "They Can Deliver the Goods, But They Clog Landfills
And Gobble Up Trees". The article reports that one third of US
landfills will not take pallets, and others charge fees for taking
pallets. Most pallets are eventually abandoned, left to pile up as
a dangerous nuisance.
[0008] These issues are not of great concern with plastics and
paper/corrugated packaging materials, as pallets made of these
materials are recyclable. It is worth noting that recyclable
paper-based pallets are already favored for export to
environmentally concerned countries such as the various EU
members.
[0009] A further deficiency of wood pallets revolves around the
effect of their weight on a whole range of issues, such as added
transportation costs, and handling difficulties for workers. The
average weight of a 48".times.40" block style wood pallet with four
way entry is approximately 45 lbs. The shipper must pay for the net
weight of the pallet as part of the total transportation cost of
the shipment, in all less-than-truckload (so-called "LTL") volumes,
as well as all domestic and international shipments by air. This
added expense is significant. For example, the average domestic LTL
trucking rate is $0.33 per lb. This means that it costs the shipper
$14.85 to ship each pallet without any freight on it. With domestic
air rates ranging from $0.60-$1.50 per lb (depending on the service
level), and export air rates at $1.00 per lb., the expense of
shipping the pallet itself can have a profound impact on the total
transportation cost.
[0010] The handling of wood pallets by warehouse workers has been
an issue for many years in terms of the repetitive lifting of heavy
weights and injuries caused by splinters, exposed nails, and
falling pallets. The issue of weight has grown as a concern since
women are joining the traditionally male workforce in warehouses
and shipping docks. OSHA has pressed U.S. industries to minimize
human lifting weights to 45 lbs. It is common knowledge that the
weight and condition of wood pallets have contributed to workmen's
compensation claims in the transportation industry and has become a
cost factor regarding its use. Government regulations and company
work rules usually require that a damaged wood pallet be taken out
of service and either repaired or replaced unless the damage is
very minor.
[0011] Still a further deficiency of wood pallets is the quality of
the top load-bearing surface. Very frequently, the top surface is
made of rough and uneven wood, which can cause damage to outer
packaging, and sometimes to the goods themselves. While this might
seem minor, in normal warehouse conditions where freight is handled
roughly and quickly, damage claims can easily result.
[0012] For decades, non-wood alternative pallet products,
particularly paper-based/corrugated and plastic products, have been
manufactured and widely distributed. Examples of such pallets are
disclosed in U.S. Pat. Nos. 5,329,861, 5,595,125, 5,660,118,
5,784,971, 5,934,202, 6357,364, and 6,612,207 Until the current
phytosanitary issues became an international crisis, and the
regulations to combat infestation became a certainty, these
alternative products faced a number of obstacles that limited their
ability to gain greater market share against wood pallets. One such
obstacle is that generally pallets made from durable, recyclable,
and reusable plastics, are regarded as far too expensive for
single-use applications, and have only gained market share in
closed loop transport systems where they can be recovered. Good
plastic pallets generally cost between $75 and $90 each. Another
obstacle has been that traditional paper-based pallets made from
"homogeneous" materials such as Kraft paper honeycomb and
corrugated paperboard have never enjoyed a significant price
advantage over new wood pallets, or a cost advantage when compared
to used/reconditioned wood pallets.
[0013] A further obstacle has been that traditional paper-based
pallets generally cannot match many performance attributes inherent
to wood pallets (especially relating to the deck support aspect of
load-bearing). No currently offered paper pallet even claims to be
strong enough to be used in unsupported warehouse racking systems.
Wood pallets can be placed side by side in a warehouse rack loaded
with freight, and stacked one on top of the other to a reasonable
height limit. Such is not true of currently known paper-based
pallets.
[0014] Still a further obstacle facing paper-based pallets is that
they have not been able to overcome their greatest perceived
weakness; that they cannot be exposed to any water, or be used in a
wet environment. Consequently, unlike wood pallets, paper pallets
cannot be stored outside, which is a common practice in many area
of this country. Although U.S. Pat. No. 5,359,861 does briefly
mention that portions of the paper-based pallet could be coated
with polyethylene, this process may not be very effective and
typically is high in cost.
[0015] What is desired, therefore, is a pallet system which is
constructed from a wood alternative, which does not present a
hazard of facilitating the migration of pests, which is not subject
to the treatment requirements imposed by governmental agencies,
which is relatively inexpensive to create and use, which does not
pose great environmental concerns, which is lower in weight than
wood pallets, which has a top surface which is not prone to
damaging goods shipped thereon, which has a strength similar to
that of wood pallets, and which is water resistant such that it can
be used in humid or wet environments.
SUMMARY OF THE EMBODIMENTS OF THE INVENTION
[0016] Accordingly, it is an object of the present invention to
provide a pallet system which is constructed from a wood
alternative.
[0017] Another object of the present invention is to provide a
pallet system having the above characteristics and which does not
present a hazard of facilitating the migration of pests.
[0018] A further object of the present invention is to provide a
pallet system having the above characteristics and which is not
subject to the treatment requirements imposed by governmental
agencies.
[0019] Still another object of the present invention is to provide
a pallet system having the above characteristics and which is
relatively inexpensive to create and use.
[0020] Yet another object of the present invention is to provide a
pallet system having the above characteristics and which does not
pose great environmental concerns.
[0021] Still yet another object of the present invention is to
provide a pallet system having the above characteristics and which
is lower in weight than wood pallets.
[0022] Still a further object of the present invention is to
provide a pallet system having the above characteristics and which
has a top surface which is not prone to damaging goods shipped
thereon.
[0023] Yet still a further object of the present invention is to
provide a pallet system having the above characteristics which has
strength similar to that of wood pallets.
[0024] Still yet another object of the present invention is to
provide a pallet system having the above characteristics and which
is water resistant such that it can be used in humid or wet
environments.
[0025] These and other objects are achieved according to one
embodiment of the present invention by provision of a shipping
pallet comprising a deck having an upper surface and an opposing
lower surface and a plurality of deck support structures, each of
the deck support structures having a plurality of prongs protruding
from an upper surface thereof. The plurality of prongs of each deck
support structure penetrate and engage the lower surface of the
deck so as to cause the plurality of deck support structures to be
attached to the deck.
[0026] In some embodiments, the deck comprises corrugated board
having at least one intermediate corrugated member sandwiched
between linerboard facings. In certain of these embodiments, the
deck comprises triple wall corrugated board having three
intermediate corrugated members sandwiched between four linerboard
facings. In certain embodiments, the intermediate corrugated
members and the linerboard facings are treated internally for water
resistance using a waterproofing chemical treatment or sizing,
whereby the shipping pallet is water resistant. In certain of these
embodiments, the outer linerboard facings are also coated with a
waterproof coating, whereby the shipping pallet is waterproof. In
other embodiments, the deck comprises a Kraft paper honeycomb panel
having a honeycomb core sandwiched between linerboard facings. In
certain of these embodiments, the honeycomb core and the linerboard
facings are treated internally for water resistance using a
waterproofing chemical treatment or sizing, whereby the shipping
pallet is water resistant. In certain embodiments, the linerboard
facings are coated with a waterproof coating, whereby the shipping
pallet is waterproof.
[0027] In some embodiments, each of the plurality of deck support
structures comprises a unitized extruded or molded part formed from
a plastic material. In some embodiments, each of the plurality of
deck support structures comprises at least one of structural foam
polypropylene and structural foam polyethylene. In some
embodiments, each of the plurality of deck support structures is
formed from a recycled plastic material. In some embodiments, each
of the plurality of deck support structures is formed from a virgin
plastic material. In some embodiments, each of the plurality of
deck support structures comprises three post sections set between a
lower skid and an upper rail. In certain of these embodiments, the
plurality of prongs of each deck support structure, protrude from
an upper surface of the upper rail.
[0028] In some embodiments, each of the plurality of prongs
comprises a barb so as to enhance attachment between the plurality
of deck support structures and the deck. In certain of these
embodiments, the barb is formed in a substantially vertical surface
of each of the plurality of prongs. In certain of these
embodiments, each of the plurality of prongs further comprises a
sloped surface, and the barb is positioned on a side of the prong
opposite to the sloped surface. In certain embodiments, the barb is
formed in a sloped surface of each of the plurality of prongs.
[0029] In some embodiments, each of the plurality of deck support
structures is attachable without tools to the deck by forcing each
of the plurality of deck support structures and the deck together
such that the plurality of prongs of each deck support structure
penetrate and engage the lower surface of the deck. In some
embodiments, each of the plurality of deck support structures is
detachable without tools from the deck by gripping an end of each
of the plurality of deck support structures adjacent an end thereof
and pulling each of the plurality of deck support structures away
from the deck.
[0030] In accordance with another embodiment of the present
invention, a shipping pallet comprises a deck having an upper
surface and an opposing lower surface, the deck comprising
corrugated board having at least one intermediate corrugated member
sandwiched between linerboard facings. The shipping pallet also
comprises a plurality of deck support structures, each of which
comprises a unitized extruded or molded part formed from a plastic
material, each of the deck support structures having a plurality of
prongs protruding from an upper surface thereof. The plurality of
prongs of each deck support structure penetrate and engage the
lower surface of the deck so as to cause the plurality of deck
support structures to be attached to the deck, and each of the
plurality of prongs comprises a barb so as to enhance attachment
between the plurality of deck support structures and the deck. Each
of the plurality of deck support structures is attachable without
tools to the deck by forcing each of the plurality of deck support
structures and the deck together such that the plurality of prongs
of each deck support structure penetrate and engage the lower
surface of the deck, and each of the plurality of deck support
structures is detachable without tools from the deck by gripping an
end of each of the plurality of deck support structures adjacent an
end thereof and pulling each of the plurality of deck support
structures away from the deck.
[0031] In some embodiments, the deck comprises triple wall
corrugated board having three intermediate corrugated members
sandwiched between four linerboard facings. In some embodiments,
the intermediate corrugated members and the linerboard facings are
treated internally for water resistance using a waterproofing
chemical treatment or sizing, whereby the shipping pallet is water
resistant. In certain of these embodiments, the linerboard facings
are coated with a waterproof coating, whereby the shipping pallet
is waterproof.
[0032] In some embodiments, each of the plurality of deck support
structures comprises at least one of structural foam polypropylene
and structural foam polyethylene. In some embodiments, each of the
plurality of deck support structures comprises three post sections
set between a lower skid and an upper rail. In certain of these
embodiments, the plurality of prongs of each deck support
structure, protrude from an upper surface of the upper rail.
[0033] In some embodiments, the barb is formed in a substantially
vertical surface of each of the plurality of prongs. In certain of
these embodiments, each of the plurality of prongs further
comprises a sloped surface, and the barb is positioned on a side of
the prong opposite to the sloped surface. In some embodiments, the
barb is formed in a sloped surface of each of the plurality of
prongs.
[0034] In accordance with a further embodiment of the present
invention, a shipping pallet comprises a deck having an upper
surface and an opposing lower surface, the deck comprising triple
wall corrugated board having three intermediate corrugated members
sandwiched between four linerboard facings. The shipping pallet
also comprises a plurality of deck support structures, each of
which comprises a unitized extruded or molded part formed from at
least one of structural foam polypropylene and structural foam
polyethylene, each of the deck support structures comprising three
post sections set between a lower skid and an upper rail, and
having a plurality of prongs protruding from an upper surface of
the upper rail. The plurality of prongs of each deck support
structure penetrate and engage the lower surface of the deck so as
to cause the plurality of deck support structures to be attached to
the deck. Each of the plurality of prongs comprises a barb so as to
enhance attachment between the plurality of deck support structures
and the deck, the barb being formed in a substantially vertical
surface of each of the plurality of prongs, which substantially
vertical surface is positioned opposite to a sloped surface of the
barb. Each of the plurality of deck support structures is
attachable without tools to the deck by forcing each of the
plurality of deck support structures and the deck together such
that the plurality of prongs of each deck support structure
penetrate and engage the lower surface of the deck, and each of the
plurality of deck support structures is detachable without tools
from the deck by gripping an end of each of the plurality of deck
support structures adjacent an end thereof and pulling each of the
plurality of deck support structures away from the deck.
[0035] In some embodiments, the intermediate corrugated members and
the linerboard facings are treated internally for water resistance
using a waterproofing chemical treatment or sizing, whereby the
shipping pallet is water resistant. In certain of these
embodiments, the linerboard facings are coated with a waterproof
coating, whereby the shipping pallet is waterproof.
[0036] The invention and its particular features and advantages
will become more apparent from the following detailed description
considered with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a perspective view showing an assembled pallet in
accordance with an embodiment of the present invention;
[0038] FIG. 2 is a perspective exploded view, partially cut away,
showing an unassembled pallet in accordance with an embodiment of
the present invention;
[0039] FIGS. 3A-3C are, respectively, perspective, side and front
views showing portions of an embodiment of the rail portions of the
pallets shown in FIGS. 1 and 2;
[0040] FIGS. 4A-4C are, respectively, perspective, side and front
views showing portions of an embodiment of the rail portions of the
pallets shown in FIGS. 1 and 2; and
[0041] FIG. 5 is a perspective view showing an embodiment of the
rail portions of the pallets shown in FIGS. 1 and 2.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0042] The present invention is directed to a hybrid pallet system
having components formed from various materials. The pallet
immediately distinguishes itself from known prior art pallets, all
of which (whether wood, plastic, or paper-based) are made
completely from those homogeneous materials. Referring to FIGS. 1
and 2, the pallet 10 includes three deck support structures 12,
each preferably made as a unitized extruded or molded part from a
plastic material, either new or recycled, and a deck 14 made from a
layered paper material, also either new or recycled, preferably
having a corrugated or honeycomb configuration.
[0043] Each unitized deck support structure 12 includes three post
sections (as pallet feet) 16, set between a skid (which will rest
on the ground) 18, and a rail (upon which the pallet deck will be
positioned) 20. This unitized I-beam design using strong yet
flexible plastic, or plastic composite material, gives the pallet a
load-bearing capacity competitive with wood, and superior to that
of corrugated or honeycomb pallet feet. The three support
structures 12 are designed and configured with openings 22 between
post sections 16 to facilitate four-way entry (either by forklift
or pallet jack), and enable the pallet 10 to be used on conveyers
or roller-systems for maximum versatility.
[0044] The support structures 12 can made of, among other things,
virgin or recycled "structural foam" polypropylene, polyethylene,
or other composite material of recycled plastic, becoming more
commonly available. Structural foam injection molding is
advantageous because it is a single step process, and can reduce
the weight of each support structures 12 by up to approximately
33%, which is very desirable for a shipping pallet. Along with
weight reduction, less plastic, whether virgin or recycled (or even
a combination of both which can be used), substantially reduces the
unit cost of each support structures 12. A multiple cavity mold of
the support structures 12 can be designed for use with structural
foam presses that are operated by injection molders in North
America and various parts of the world, so the part can be produced
and distributed at a competitive cost in volume. The rails made
from polypropylene and/or polyethylene would be reusable and
recyclable.
[0045] The support structures 12 are generally uniform, of one
"standard size," and are completely interchangeable. This
simplifies the process of shipping the unassembled deck support
parts, pallet assembly, distribution, and replacement of broken
parts. In terms of the business model, making the support
structures 12 uniform and interchangeable creates significant
economies of scale to reduce the cost of producing the part,
especially as volumes increase. This allows for a pallet
constructed in accordance with the present invention to be priced
competitively with new wood pallets.
[0046] Standardizing the support structures 12 also facilitates
another significant operational and marketing feature. It allows
for varying size decks 14 to be used without having to change the
size of the support structures 12, building even greater
versatility into this system for shippers that use multiple size
pallets in their business.
[0047] The load-bearing top deck 14 may be made from, for example,
triple wall corrugated board as is shown in FIG. 1. Triple wall
corrugated board, as defined by the Uniform Freight Classification
Rules, is a structure formed by four flat facings 24 and three
intermediate corrugated members 26. The four flat facings 24 are
linerboard. For the two "outer" linerboard facings 24, the
paperweight (min/max) is preferably 69190 or 90190 . The preferred
paperweights of the two "inner" linerboard facings 24 (min/max) are
42# or 69#. The preferred paperweights for the three intermediate
corrugated members 26 are (min/max) 26# or 33190 . The preferred
corrugation (wave shape) fluting configuration of the three
intermediate corrugated members 26 are either AAA or ACC. A-flute
has 33 flutes (plus or minus 3) per linear foot, and an approximate
height of {fraction (3/16)}", and C-flute has 39 flutes per linear
foot (plus or minus 3) and an approximate height of {fraction
(9/64)}" (the heights not including the thickness of the linerboard
facings 24).
[0048] The load-bearing top deck 14 may alternatively be made from
fabricated Kraft paper honeycomb panels, which are 100% recyclable,
as shown in FIG. 2. Kraft paper honeycomb sandwiched panels (which
also derive their strength from an I-beam design), provide the
highest strength to weight ratio of any available material. The use
of this light-weight material mitigates and offsets the weight of
the plastic deck supports 12, while still maintaining the total
weight of the pallet 10 significantly less than that of a wood
pallet (though somewhat higher than a homogeneous paper-based
pallet).
[0049] However, as is known in the art, standard triple wall
corrugated board and standard Kraft paper honeycomb are not
water-proof or resistant to moisture. As with all paper-based
pallet solutions, this puts triple wall corrugated board and
honeycomb at a disadvantage against waterproof materials, and has
served to limit their application to environments with no risk of
moisture or water exposure. Applicants have, however, developed and
successfully tested moisture resistant and virtually waterproof
corrugated paper board, and honeycomb pallet decks. The water
resistant deck is comprised of honeycomb core and/or corrugated
members and linerboard papers that have been treated internally for
water resistance, using a waterproofing chemical treatment or
"sizing." Although any of numerous chemical treatments may be
employed, it has been found that chemical compounds designed to
make paper non-wicking and water resistant provide acceptable
results. Of course, it should be recognized that numerous other
chemical treatments may be employed.
[0050] The waterproof version of the deck features linerboard
facings that have additionally been treated with waterproof
coatings to effectuate the highest level of protection. Although
any of numerous coatings may be employed, it has been found that
coatings designed for water and/or oil repellency provide
acceptable results. Of course, it should be recognized that
numerous other coatings may be employed.
[0051] Each of three versions of the pallet deck is particularly
designed to address a separate segment of the market. The untreated
standard triple wall corrugated board or honeycomb deck can be
offered as a general purpose platform, while the water resistant
type can be used in any transit application; for all weather
conditions. In many instances the deck itself (which is generally
loaded with freight prior to exposure to water or moisture) does
not need to be water resistant or waterproof. Regardless of which
type of deck is employed, the standardized deck support structures
are always able to withstand moisture, rain, or standing water
during transit, a major advantage against all of the known
paper-based pallet alternatives.
[0052] A main purpose for the waterproof version of the pallet deck
is to address a very unique and challenging market segment, and to
replace wood pallets in a niche market they have always owned--the
shipment of fresh and frozen agricultural/produce commodities,
meat, and poultry products. These products are loaded in wet
conditions, or are subjected to very high moisture or wet
conditions as part of the packing or shipping process itself. Such
products include fresh asparagus, broccoli, and cherries, as well
as fresh/frozen meat, poultry etc. In those type of shipping
environments (as well as many others), wood pallets are stored
outside of warehouses to save precious space. This is particularly
common in the relatively dry regions of the west and southwest.
[0053] These are huge markets that all paper-based pallets (as well
as plastic pallets which are considered to be far too expensive for
single-use) are barred from entering, due to the "water exposure
and storage issue." According to forwarder feedback, if there were
a viable non-wood alternative, the industry would choose to move
away from wood pallets for these applications, because of all of
their well-known disadvantages. The pallet of the present
invention, with a waterproof deck and waterproof support
structures, is able to meet this challenge. At the very least the
un-assembled deck support parts could be stored efficiently in or
outside of a warehouse in those areas that follow that custom.
[0054] Referring now to FIGS. 3A-5, unlike prior art pallets, no
glues, connecting hardware, or tools are required to assemble or
disassemble the pallet 10. Instead, the top surface of each support
structure 12 is provided with a plurality of prongs 28, 28', 28"
protruding therefrom, which prongs 28, 28', 28" have pointed tips
32 adapted to puncture the lower surface of the top deck 14, and
may include a barb or undercut 30 (best seen in FIGS. 3B and 4B) to
provide enhanced connection therebetween. The prongs 28, 28', 28"
allow for the support structures 12 to be quickly and easily
attached to and removed from the top deck 14. The prongs 28, 28',
28" may be elongated in shape (as shown in FIGS. 5) or may be
formed as discrete protuberances (as shown in FIGS. 3A and 4A).
[0055] More specifically, with reference particularly to prongs 28,
28' shown in FIGS. 3A-4C, the length of each prong 28, 28' is such
that it will penetrate the outer facing of the deck 14 and,
particularly in the case of the triple wall corrugated board, just
reach but not press into the far side of the first flute and its
adjacent inner facing. The length is maximized so that its tip and
tapered sides facilitate easier penetration of the outer facing.
Barb or undercut 30 is cut on the opposite of the sloped side 34 of
the prong 28 and extends down to the bottom of the prong's base to
catch and latch-up with the outer facing of the deck 14 as it
arrives during penetration. Since the puncture will cause the edges
of the outer facing to curl upwards towards the top of the prong
28, 28' during penetration, the barb or undercut 30 is made high
enough to catch that curl. The barbed or undercut side of the prong
28 may be vertical whereas its opposite side is sloped (as shown in
FIG. 3B), so that as the prong 28 enters the substrate, the slope
is forcing or pushing the paper against the notch and locking the
paper against it, or the barbed or undercut side of the prong 28'
may also be sloped (as shown in FIG. 4B). The slope of the opposite
two sides 36, 36' are angled and spread wide enough to give the
prong sufficient bending strength and thus prevent it from snapping
off. The entirety of each of the two opposite sides 36' may be
sloping (as shown in FIG. 4C) or a portion thereof may be vertical
(as shown in FIG. 3C). The design of the prongs 28, 28', 28" gives
the paper enough shearing surface (edge) to keep the deck 14 from
sliding on the support structures 12, as when full, pallets are
loaded and pushed against one another. The edges of the prongs 28,
28', 28" may have a slight radius, as is typically found in an
injection molded plastic part, so that the paper tear forces are
more effective, although the prong 28, 28', 28" will work
adequately if the point 32 and edges are sharp. Additional notching
can be done on one or more of the opposite sides of the prong 28,
28', 28" if desired.
[0056] The finished, unassembled pallet decks 14 can be shipped by
rail or truck to strategic assembly/distribution locations from
plant locations most proximate to the customer. This can be
accomplished efficiently and at a relatively low cost, since the
decks are relatively flat and pack well into containers, as is the
case with the deck supports. This is a major strategic advantage
since all wood and non-wood-alternative pallet producers ship their
pallets fully assembled from their various plant locations to
distributors or customers, which adds significant freight costs for
the customer.
[0057] The method of attaching the support structures 12 to the
paper deck 14 can be done in the field; done by an apprentice; done
without the need of any extra materials, parts or bonding agents;
done for any configuration of pallet; done quickly; and done with
precision, security and quality. The pallet 10 is shipped as two
components, the deck 14 and the three support structures 12 (often
referred to as rails, feet, pads, legs, etc). Each support
structure 12 has a configuration of small prongs 28, 28', 28" on
the top cross-member 20 that penetrate the deck surface and latch
onto the deck's facing. This latch-up is sufficient enough so that
the support structures 12 will remain attached with normal handling
of a pallet 10. However, it is designed such that with a tug from
an end of the support structure 12, it can be unseated and then
easily removed for reuse.
[0058] Having a pallet deck 14 removable from reusable deck support
structures 12 has numerous marketing and operational advantages. At
minimal additional cost, a "used" deck 14 can be removed if
required and replaced in minutes at the other end of a distribution
system, and thus be brought into compliance "again" from the
standpoint of regulated industries that require the use of only new
pallets (for sanitary reasons). There are many industries that fall
into this category such as healthcare and pharmaceuticals. As
interchangeable parts, the unassembled deck supports 12 can be less
expensively recaptured between locations in a closed loop
distribution system. The objective, however, is to keep the cost of
those parts low enough that the pallet can still be priced as a
one-way pallet. The pallet of the present invention has also been
designed to be used in warehouse racking systems.
[0059] The present invention, therefore, provides a pallet system
which is constructed from a wood alternative, which does not
present a hazard of facilitating the migration of pests, which is
not subject to the treatment requirements imposed by governmental
agencies, which is relatively inexpensive to create and use, which
does not pose great environmental concerns, which is lower in
weight than wood pallets, which has a top surface which is not
prone to damaging goods shipped thereon, which has a strength
similar to that of wood pallets, and which is water resistant such
that it can be used in humid or wet environments.
[0060] Although the invention has been described with reference to
a particular arrangement of parts, features and the like, these are
not intended to exhaust all possible arrangements or features, and
indeed many other modifications and variations will be
ascertainable to those of skill in the art.
* * * * *