U.S. patent application number 11/528868 was filed with the patent office on 2007-03-29 for foldable support leg and pallet assembly formed therefrom.
Invention is credited to Damian Anthony Larson, Daniel Andrew Larson, William Gale Teags.
Application Number | 20070068426 11/528868 |
Document ID | / |
Family ID | 37892323 |
Filed Date | 2007-03-29 |
United States Patent
Application |
20070068426 |
Kind Code |
A1 |
Teags; William Gale ; et
al. |
March 29, 2007 |
Foldable support leg and pallet assembly formed therefrom
Abstract
A support leg includes a sheet of material configured into a
sequence of adjacent panels and including a first tab, a first
cutout configured to receive the first tab being formed within one
of the panels, wherein the sheet is foldable into a nested panel
structure defining an interior cavity. A pallet deck includes a
sheet of material having a plurality of first cutouts and second
cutouts defined therein, wherein each first cutout is dimensioned
to allow insertion of the at least one tab and at least one panel
of the foldable support leg and each second cutout is dimensioned
to allow insertion of the at least one tab, each second cutout
being spaced apart from each first cutout such that the at least
one panel is able to substantially extend therebetween. A pallet
assembly is formed by mating a plurality of support legs to a
pallet deck.
Inventors: |
Teags; William Gale;
(Longmont, CO) ; Larson; Damian Anthony; (Cave
Creek, AZ) ; Larson; Daniel Andrew; (Cave Creek,
AZ) |
Correspondence
Address: |
MCCORMICK, PAULDING & HUBER LLP
CITY PLACE II
185 ASYLUM STREET
HARTFORD
CT
06103
US
|
Family ID: |
37892323 |
Appl. No.: |
11/528868 |
Filed: |
September 28, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60721621 |
Sep 29, 2005 |
|
|
|
Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 2519/00412
20130101; B65D 2519/00338 20130101; B65D 2519/00019 20130101; B65D
2519/00557 20130101; B65D 19/0028 20130101; B65D 19/40 20130101;
B65D 2519/00567 20130101; B65D 2519/00054 20130101; B65D 2519/0087
20130101; B65D 2519/00288 20130101; B65D 2519/00323 20130101; B65D
2519/00985 20130101 |
Class at
Publication: |
108/051.3 |
International
Class: |
B65D 19/00 20060101
B65D019/00 |
Claims
1. A support leg comprising: a sheet of material configured into a
sequence of adjacent panels and including a first tab, a first
cutout configured to receive the first tab being formed within at
least one of the panels; wherein the sheet is foldable into a
nested panel structure having the first tab inserted into the first
cutout and defining an interior cavity.
2. The support leg of claim 1, wherein the interior cavity defined
by the sheet upon folding has a substantially rectangular cross
section.
3. The support leg of claim 2, wherein a first panel will
diagonally traverse the interior cavity when the sheet is folded
into the nested panel structure.
4. The support leg of claim 3, wherein a second panel will
diagonally traverse the interior cavity when the sheet is folded
into the nested panel structure.
5. The support leg of claim 4, wherein the first and second panels
will diagonally traverse the interior cavity at angles offset by
approximately 90 degrees when the sheet is folded into the nested
panel structure.
6. The support leg of claim 3, wherein a second cutout for
accommodating the first tab after insertion into the first cutout
is defined in at least one of the panels diagonally traversing the
interior of the rectangular solid.
7. The support leg of claim 6, wherein a third and fourth panel
define opposing sides of the interior cavity when the sheet is
folded into the nested panel structure, the first cutout being
defined within the third panel, the first tab extending between the
third and fourth panels when the first tab is inserted into the
first cutout.
8. The support leg of claim 5, wherein a third panel defines one of
the sides of the rectangular solid and a fourth panel lies inside
of and adjacent to the third panel when the sheet is folded into
the nested panel structure, the second panel extending from the
fourth panel.
9. The support leg of claim 8, wherein the third panel is cut so as
to form a second tab, and the fourth panel defines a second cutout,
the second tab being insertable into the second cutout to inhibit
unfolding of the support leg when the sheet is at least partially
folded into the nested panel structure.
10. The support leg of claim 3, wherein a second panel traverses
the interior cavity substantially perpendicular to the panels
defining the sides of the cavity when the sheet is folded into the
nested panel structure.
11. The support leg of claim 10, wherein a second cutout is defined
within the first panel, the second cutout accommodating the second
panel when the sheet is folded into the nested panel structure.
12. The support leg of claim 2, wherein the first cutout is defined
within a first panel and the first tab extends from a second panel,
the second panel overlying at least a portion of the first panel
when the sheet is folded into the nested panel structure.
13. The support leg of claim 12, wherein the first and second
panels are spaced apart when the sheet is folded into the nested
panel structure such that another sheet of material, of at least
approximately the same thickness as the sheet of material, can be
accommodated between the first and second panels.
14. A pallet assembly comprising: a plurality of support legs, at
least one support leg folded from a single sheet of material and
including a first tab and defining a first cutout for receiving the
first tab therein; and a pallet deck, at least one second cutout
being defined within the pallet deck; wherein the at least one
support leg is secured to the pallet deck by the insertion of the
first tab through the at least one second cutout prior to insertion
into the first cutout.
15. The pallet assembly of claim 14, wherein the sheet of material
forming the support leg is configured into a sequence of adjacent
panels that are folded into a nested panel structure defining an
interior cavity.
16. The pallet assembly of claim 15, wherein the interior cavity
has a substantially rectangular cross section and two of the panels
diagonally traverse the interior cavity, the two panels being
offset from one another by approximately 90 degrees.
17. The pallet assembly of claim 14, wherein the sheet of material
folded to form the at least one support leg includes a first panel
and a second panel, the first cutout being defined within the first
panel and the first tab extending from the second panel, the pallet
deck being accommodated between the first and second panels.
18. The pallet assembly of claim 17, wherein at least one third
cutout is defined within the pallet deck, the first tab and the
second panel being inserted through the third cutout prior to
insertion of the first tab through the second cutout.
19. The pallet assembly of claim 14, wherein the pallet assembly
further comprises a shipping monitoring instrument, the shipping
monitoring instrument being located between the pallet deck and the
at least one support leg.
20. The pallet assembly of claim 17, wherein the pallet assembly
further comprises a shipping monitoring instrument, the shipping
monitoring instrument being located between the pallet deck and the
first panel.
21. The pallet assembly of claim 14, wherein the pallet deck
includes a plurality of foldable edge panels substantially
surrounding the pallet deck perimeter.
22. The pallet assembly of claim 21, wherein the adjacent edge
panels are folded away from the support legs to form a tray.
23. The pallet assembly of claim 21, wherein the adjacent edge
panels are folded toward the support legs to form a skirt at least
partially concealing the support legs.
24. A pallet deck comprising: a sheet of material having a
plurality of first cutouts and a plurality of second cutouts
defined therein; wherein each first cutout is dimensioned to allow
insertion of at least one tab and at least one panel of a
corresponding foldable support leg and each second cutout is
dimensioned to allow insertion of the at least one tab, each second
cutout being spaced apart from each first cutout such that the at
least one panel is able to substantially extend therebetween.
25. The pallet deck of claim 24, wherein there are two second
cutouts associated with each first cutout.
26. The pallet deck of claim 24, wherein the first cutouts
associated with support legs to be secured along an edge of the
pallet deck are formed as recesses along the edge.
27. The pallet deck of claim 24, wherein the pallet deck includes a
plurality of foldable edge panels substantially surrounding the
pallet deck perimeter.
28. The pallet deck of claim 27, wherein adjacent foldable edge
panels are releasably connectable when folded at an angle of
approximately 90 degrees relative to the pallet deck.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/721,621, filed on Sep. 29, 2005, the contents of
which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to pallet
assemblies, and particularly to pallet assemblies made from sheets
of corrugated materials like plastic and paper.
BACKGROUND OF THE INVENTION
[0003] Wooden pallets used in connection with shipping and other
activities are ubiquitous. However, there are many drawbacks
associated with wooden pallets. Wooden pallets are heavy and are
prone to infestation by various insects and to fungal growth. The
need to check wooden pallets for infestation and/or fungus, and to
treat affected pallets can cause serious delay and expense for
pallet users, especially in international shipping activities.
Before use, wooden ballets must be shipped to prospective points of
use. During such shipping, wooden pallets occupy a relatively large
volume, thus limiting the number that can be shipped in a given
conveyance. Once used, wooden pallets are difficult to recycle and
consequently end up in landfills in excessive numbers.
[0004] Materials like plastic and paper can be advantageous
relative to wood as plastic and paper are lighter, and either
inherently resistant to infestation and fungal growth or easily
treatable to resist both. Recycling facilities readily accept
plastic and/or paper. Various attempts have been made to design
corrugated plastic or paper pallets. Some plastic pallets are
individually molded for a specific use. Such pallets are relatively
expensive to produce initially and require nearly the same volume
during shipping as wooden pallets.
[0005] Other attempts have been made to use corrugated paper or
plastic, but without deviating far from conventional pallet design.
These types of pallets are generally constructed using conventional
pallet elements cut from multiple plies of corrugated material and
then assembled. Because of the large amount of material used, such
pallets do not fully take advantage of the lightweight nature of
plastic and/or paper, and require as much, or nearly as much, space
during shipping as conventional pallets.
[0006] Finally, some attempts have been made to construct pallets
using fewer plies of paper or plastic, while typically trying to
increase strength with some combination of folding and use of more
rigid materials. Such pallets are difficult to assemble, require
additional adhesives and fasteners, and only achieve a limited
benefit over wood when more rigid materials are included.
[0007] From the foregoing it can be seen that there is a need for a
lightweight pallet constructed from plastic and/or paper that
exhibits sufficient load-bearing capacity and rigidity while
capable of occupying a small volume during shipping to a point of
use and adapted for easy assembly at the point of use without the
need for adhesives, discrete fasteners, or the like.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a
foldable support leg that is completely flat when unfolded, but
provides superior rigidity and load-bearing capacity once folded,
without requiring any adhesives, discrete fasteners, or the
like.
[0009] It is a further object of the present invention to provide a
foldable support leg adapted for securely mating, without requiring
adhesives, discrete fasteners, or the like, with a load bearing
surface, such as the deck of a pallet.
[0010] According to an embodiment of the present invention, a
pallet assembly includes a plurality of support legs, at least one
support leg folded from a single sheet of material and including a
first tab and defining a first cutout for receiving the first tab
therein, and a pallet deck, at least one second cutout being
defined within the pallet deck wherein the at least one support leg
is secured to the pallet deck by the insertion of the first tab
through the at least one second cutout prior to insertion into the
first cutout.
[0011] According to an aspect of the present invention, the support
leg includes a sheet of material configured into a sequence of
adjacent panels and including the first tab, the first cutout
configured to receive the first tab being formed within at least
one of the panels, wherein the sheet is foldable into a nested
panel structure having the first tab inserted into the first cutout
and defining an interior cavity.
[0012] According to another aspect of the present invention, the
pallet deck includes a sheet of material having a plurality of
first cutouts and a plurality of second cutouts defined therein,
wherein each first cutout is dimensioned to allow insertion of at
least one tab and at least one panel of a corresponding foldable
support leg and each second cutout is dimensioned to allow
insertion of the at least one tab, each second cutout being spaced
apart from each first cutout such that the at least one panel is
able to substantially extend therebetween.
[0013] According to a further aspect of the present invention, two
diagonal panels traverse the interior cavity of the support leg,
offset by approximately 90 degrees, substantially enhancing the
structural conformity and load bearing capacity of the support
leg.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a pallet assembly including
a pallet deck and a plurality of foldable support legs, according
to an embodiment of the present invention;
[0015] FIG. 2 is a perspective view of one of the support legs of
FIG. 1 completely unfolded;
[0016] FIGS. 3-8 are perspective views of the support leg of FIG.
2, in various states of folding;
[0017] FIG. 9 is the support leg of FIG. 2 fully folded;
[0018] FIG. 10 is a perspective view of the pallet deck of FIG.
1;
[0019] FIGS. 11 and 12 are perspective views showing various stages
of securing the supports legs to the pallet deck of FIG. 10;
[0020] FIG. 13 is a perspective view of a fully unfolded support
leg, according to another embodiment of the present invention;
[0021] FIGS. 14-16 are perspective views of the support leg of FIG.
13, in various states of folding;
[0022] FIG. 17 is a perspective view of the support leg of FIG. 13
fully folded;
[0023] FIG. 18 is a perspective view of a pallet deck, according to
another embodiment of the present invention; and
[0024] FIGS. 19 and 20 are perspective views of pallet assemblies
including the pallet deck of FIG. 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to FIG. 1, a pallet assembly 10 is formed from a
plurality of foldable support legs 12 mated to a pallet deck 14.
The support leg will be described in reference to FIGS. 2-9.
Referring to FIG. 2, each support leg 12 is folded from a sheet 20
of material. The sheet 20 of material is configured into a sequence
of adjacent panels and tabs. The panels include a bottom panel 22,
first and second side panels 24, 26, a top panel 28, first and
second diagonal panels 30, 32, a diagonal offset panel 34, and
first and second deck retention panels 36, 38. Together the panels
are all foldable to form a nested panel structure, the top, bottom
and side panels 22-28 defining an interior cavity, with the
diagonal panels 30, 32 and the diagonal offset panel 34 forming an
internal support structure within the cavity, as will be described
below. The terms top, bottom and side refer, as used herein, to the
orientation of the support leg 12 when mated with the pallet deck
14 during conventional use of the pallet assembly 10 with the
support legs 12 on the ground.
[0026] The tabs include first and second deck retention tabs 44, 46
extending from the first and second deck retention panels 36, 38,
and side panel engagement tabs 48 formed in the second side panel
20. Each deck retention tab 44, 46 includes two tab ears 48. A
plurality of cutouts are also defined in the panels. The cutouts
include first and second deck retention tab cutouts 50,52, a second
diagonal deck retention tab cutout 54 and side panel engagement tab
cutouts 56. The cooperation of the tabs and cutouts will be
described in detail below.
[0027] The folding of the sheet 20 of material to form the nested
panel structure of the support leg 12 will be explained in
reference to FIGS. 3-9. In FIG. 3, the sheet 20 is folded
approximately 90 degrees between the top panel 28 and the first
side panel 24. The second diagonal panel 32 is folded approximately
135 degrees over the diagonal offset panel 34. In FIG. 4, the
diagonal offset panel 34 is folded approximately 90 degrees
relative to the top panel 28, bringing an edge of the second
diagonal panel 32 into contact with the junction between the top
panel 28 and the first side panel 24, thereby forming a portion of
the internal support structure. Notably, the second deck retention
tab cutout 52 and the second diagonal deck retention tab cutout 54
are brought into alignment following this fold.
[0028] Referring to FIG. 5, the sheet 20 is folded approximately 90
degrees between the first side panel 24 and the bottom panel 22.
This fold brings the junction of the second diagonal panel 32 and
the diagonal offset panel 34 into contact with the junction of the
second side panel 26 and the bottom panel 22. Thus, the diagonal
offset panel 34 extends between the top panel 28 and the bottom
panel 22, adding further strength to the support leg 12 and also
forming part of the internal support structure. Also in FIG. 5, the
first diagonal panel 30 is folded approximately 135 degrees
relative to the top panel 28, bringing an edge of the first
diagonal panel 30 into contact with the junction between the bottom
panel 22 and the first side panel 24, thereby forming another
portion of the internal support structure.
[0029] The "x" structure thus formed by the first and second
diagonal panels 30, 32 can be better appreciated in reference to
FIG. 6. As the second diagonal panel 32 extends from the diagonal
offset 34 panel rather than directly from the top panel 28, the
first and second diagonal panels 30, 32 traverse the interior
cavity of the nested panel structure (as yet only partially folded)
offset from one another by an angle of 90 degrees. The "x"
structure thus formed adds greatly to the strength and rigidity of
the fully folded support leg 12.
[0030] Referring to FIG. 7, the sheet 20 is folded approximately 90
degrees between the bottom panel 22 and the second side panel 26.
This fold brings the second side panel 26 adjacent to the diagonal
offset panel 34, aligning the side panel engagement tabs 48 in the
second side panel 26 with the side panel engagement tab cutouts 56
in the diagonal offset panel 34. The side panel engagement tabs 48
are pushed inward through the side panel engagement tab cutouts 56.
Because each side panel engagement tab 48 has a head that exceeds
the width of a neck defined by each corresponding side panel
engagement tab cutout 56, the side panel engagement tabs 48 are
prevented from pully directly out of the side panel engagement tab
cutouts 56, thus securing the second side panel 26 to the diagonal
offset panel 34 and inhibiting the unfolding of the partially
folded support leg 12. Securing the support leg 12 in the
semi-folded state of FIG. 7 will be useful in connection with the
mating of the support legs 12 to the pallet deck 14, as will be
described below.
[0031] Referring to FIG. 8, the first and second deck retention
tabs 44, 46 are folded approximately 90 degrees relative to the
deck retention panels 36, 38. The tab ears 48 are each folded
approximately 90 degrees toward the top panel 28, such that the
shape of the end of each deck retention tab 36, 38 corresponds to
the shape of the deck retention tab cutouts 50, 52 in the top panel
28.
[0032] In FIG. 9, the first and second deck retention tabs 44, 46
are inserted into the first and second deck retention tab cutouts
50, 52 by folding the first and second deck retention panels 36, 38
90 degrees relative to the second side panel 26. The second
diagonal deck retention tab cutout 54 enables complete insertion of
the second deck retention tab 46 by allowing the second deck
retention tab 46 to extend through the second diagonal panel 32.
Once the tab ears 48 have been inserted through the first and
second deck retention tab cutouts 50, 52, the tab ears 48 will at
least partially unfold, preferably due to the natural tendency of
the material to unfold, preventing the deck retention tabs 44, 46
from pulling directly out of the corresponding deck retention tab
cutouts 50, 52. Portions of the second diagonal deck retention tab
cutout 54 are flared outward to accommodate the unfolding of the
tab ears 48 of the second deck retention tab 46.
[0033] In this fully folded state, the deck retention panels 36, 38
partially overlie the top panel 28, but are separated to define an
accommodation space 60. The accommodation space 60 is dimensioned
to accommodate the pallet deck 14, which, in the embodiment shown,
is approximately the same thickness as the sheet 20 from which the
support leg 12 is folded. The dimensions of the accommodation space
60 are established, on the first side panel 24 side, by the
distance 62 between the top of the tab ears 48 and the
corresponding deck retention panel 36, 38, and on the second side
panel 26 side, by the distance 64 by which the upper edge of the
second side panel 26 extends above the top panel 28.
[0034] Referring to FIG. 10, the pallet deck 14 is formed from a
single sheet of material 16 having a plurality of cutouts defined
therein. The cutouts enable the support legs to be secured to the
pallet deck, as is described in detail below. The cutouts include
elongated cutouts 70 and deck retention tab cutouts 72. The
elongated cutouts 70 are dimensioned to accommodate insertion of
both the deck retention tabs 44, 46, with tabs ears 48 unfolded,
and the deck retention panels 36, 38 of the support legs 12, as
will be described below. Where an elongated cutout 70 is located at
the edge of the pallet deck 14, the elongated cutout 70 is formed
as a recess 74 in the edge. The spacing 76 between the elongated
cutouts 70 and the corresponding deck retention cutouts 72 is
substantially equal to the length of the deck retention panels 36,
38. The deck retention tab cutouts 72 match the shape of the deck
retention tab cutouts 50, 52 in the top panels 28 of the support
legs 12.
[0035] To assemble the pallet assembly 10 securing the support legs
12 to the pallet deck 14, each support leg is first folded to the
state shown in FIG. 7, with the side panel engagement tabs 48
folded into the side panel engagement tab cutouts 56 to prevent the
partially-folded support leg 12 from unfolding. Referring to FIG.
11, the unfolded deck retention tabs 44, 46 and the deck retention
panels 36, 38 of each support leg 12 are inserted through the
corresponding elongated cutout 70. The folding of each support leg
12 is completed as described above in connection with FIGS. 8 and
9, with the addition that each deck retention tab 44, 46 is first
inserted through the corresponding deck retention tab cutout 72 of
the pallet deck 14 prior to being inserted through the deck
retention tab cutout 50, 52 of the top panel 28 of the support leg
12. The pallet deck 14 is then substantially fills the
accommodation space 60 between the deck retention panels 36, 38 and
the top panel 28 of each support leg 12. Various stages of the
folding of the deck retention tabs 44, 46 and their insertion
through the deck retention tab cutouts 72 of the pallet deck 14 are
illustrated in FIG. 12. The finished pallet assembly 10, with each
support leg 12 completely secured to the pallet deck 14, is best
seen in FIG. 1.
[0036] As the support legs and pallet deck used to form the pallet
assembly are each folded from flat sheets, it can be appreciated
that the support legs and pallet deck of the present invention can
be shipped while unfolded in large quantities to a point-of-use
while requiring far less space than conventional pallet support
elements. The support legs can then be assembled using a simple
folding process at the point-of-use. No adhesives, discrete
fasteners, and the like are required to assemble a support leg or
the pallet assembly, though these can be used, if desired. After
use, the pallets can be re-used or easily recycled, depending on
the condition of the pallet and the needs and desires of the user.
It can also be appreciated how a lightweight yet strong support leg
is formed by folding a single sheet of material. It can
particularly be appreciated that the rigidity and load-bearing
capacity of the support leg is enhanced by the internal x structure
formed by the first and second diagonal panels.
[0037] Those skilled in the art will appreciate that the present
invention is not limited to the above-described embodiment, but
that modifications, variations, and adaptations for particular
circumstances fall within the scope of the invention as herein
shown and described.
[0038] For example, preferably the sheets of material used to form
the support legs and the pallet deck are corrugated plastic or
paper (cardboard). Such materials are lightweight, low-cost,
readily recyclable, and possess (or can be imbued with during or
post-manufacture) anti-fungal and anti-infestation properties. The
superior strength and rigidity of corrugated sheets vice
non-corrugated sheets are well known. Alternately, the sheets of
material can be injection molded, which can advantageously impact
material management. It is not necessary that the pallet deck and
each support leg be made from sheets of the same material.
[0039] Since the support legs are folded from a flat sheet, the
support legs occupy substantially less volume, pre-folding. The
support leg design can be modified, as will be clear to those
skilled in the art, to be folded from sheets of various thicknesses
and material composition, and to accommodate pallet decks of
various thicknesses. The thickness and material composition of the
sheet used to form the support leg/pallet deck is largely a
function of design requirements.
[0040] While the overall dimensions of pallets are typically
standardized, it will be appreciated that the current invention
readily allows not only for pallets meeting differing standards,
but also for custom sizes and custom designs. The overall pallet
height can be adjusted, for instance, by utilizing larger support
legs and/or a thicker deck. The length and width of the pallet can
be varied by altering the dimensions of the deck and changing the
arrangement and/or number of support legs, as needed. Pallets that
are not square or rectangular can be readily produced in a similar
fashion. It will also be appreciated that a foldable support leg
according the to present invention can be used in a variety of
different applications, of which pallet assemblies are only
one.
[0041] While the support leg thus shown and described provides
excellent rigidity and strength, further modifications are possible
to further increase the strength and rigidity. For example, a sheet
of material 120 for folding a support leg 112 according to another
embodiment of the present invention is shown in FIGS. 13-17. The
reference numerals will be repeated for elements common to both
embodiments.
[0042] Referring to FIG. 13, a modified sheet 120 includes first
and second reinforcement panels 122, 124 extending from the end of
a first diagonal panel 130, and a reinforcement panel cutout 132 is
defined within the first diagonal panel 130. Also, longer first and
second deck detection tabs 144, 146 are included. Additionally, the
tab ears 150 of the first deck retention tab 144 each include an
angled edge. Each of these modifications are further described
below. Where an element is the same as in the embodiment described
above, the same reference numeral is used.
[0043] In FIG. 14, the second reinforcement panel 124 is folded
approximately 90 degrees relative to the first reinforcement panel
122. In FIG. 15, the first reinforcement panel 122 is folded 135
degrees relative to the first diagonal panel 130, such that the
second reinforcement panel 124 is inserted through the
reinforcement panel cutout 132. The first diagonal panel 130 is
then folded in the same manner as the first diagonal panel 30 the
previously described embodiment.
[0044] As can be appreciated from FIG. 16, the first reinforcement
panel 122 extends between the top and bottom panels 28, 22 adjacent
to the first side panel 24 and the second reinforcement panel 124
transverses the interior cavity perpendicularly to the top, bottom
and side panels 22-28 (although the second side panel 26 is shown
unfolded in FIG. 16 to show details of the modified internal
support structure). The first and second reinforcement panels 122,
124 thereby contribute to the internal support structure, further
increasing the strength and rigidity of the support leg 112.
[0045] Referring to FIG. 17, when the first deck retention tab 144
is inserted into the first deck retention cutout 50, the first deck
retention tab 144 extends all the way to the first diagonal panel
32, with the angled edge of the tab ears 150 preventing
interference between the tab ears 150 and the first diagonal panel
32. Similarly, when the second deck retention tab 146 is inserted
into the second deck retention tab cutout 52 and through the second
diagonal deck retention tab cutout 54, the second deck retention
tab 146 extends all the way to the bottom panel 22. Accordingly,
the modified deck retention tabs 144, 146 also form a part of the
internal support structure, adding even more strength and ridigity
to the fully folded support leg 112.
[0046] The modifications described in this alternate support leg
112 embodiment do not affect the general manner in which the
support leg 112 is secured to the pallet deck 14.
[0047] Further modifications to the pallet deck 14 can also be made
to add to the strength, rigidity and functionality of this element.
For example, referring to FIG. 18, the pallet deck 114 can include
foldable edge panels 170 substantially surrounding the pallet deck
114. Where adjacent edge panels 170 meet at corners of the pallet
deck 114, one edge panel 170 is provided with a tab arm 172 and a
slot 174 for receiving the tab arm 172 is defined in the other edge
panel 170. Referring to FIG. 19, the foldable edge panels 170 are
folded up approximately 90 degrees relative to the rest of the
pallet deck (shown mated with a plurality of support legs 12 to
form a pallet assembly 110), thus forming a lip around the edge of
the pallet deck 114. Insertion of the tab arms 172 into the slots
174 maintains the edge panels 170 in the folded condition. Products
loaded onto the pallet assembly 110 help keep the tab arms 172
engaged in the slots 174. The folded edge panels 170 along all the
edges of the pallet deck 114 increase the strength and rigidity of
the pallet assembly 110. The lip formed by the folded edge panels
170 also help retain products on the pallet deck 114 and facilitate
use of the pallet assembly 110 in connection with a hood, or
inverted, open-ended box, as used in certain shipping
applications.
[0048] Referring to FIG. 20, rather than folding the foldable edges
170 up and away from the support legs 12, the foldable edges 170
can also be folded down so as to at least partially conceal the
support legs 12. This configuration provides similar gains in
strength and rigidity, and can be useful, for example, when it is
desired to display products for sale without removing them from the
pallet assembly 110. In such a situation, the foldable edge 170
would preferably be folded up during shipping (as in FIG. 19), so
as not to interfere with the manipulation of the pallet assembly
110 by a forklift, or similar machine. At point of sale, the
foldable edge 170 would be folded down. The side of the foldable
edge 170 displayed when folded down could be pre-printed with
words, pictures, symbols, or the like, and could replace the skirt
frequently used to conceal pallets holding goods for sale.
[0049] The modifications to the pallet deck in this additional
embodiment would, like the alternate support leg embodiment, not
affect the general manner in which support legs are secured to the
pallet deck.
[0050] Additionally, various shipping monitoring instruments are
advantageously utilizable in connection with the present invention.
A variety of shipping monitoring instruments are known in the art,
such as radio-frequency identification (RFID) devices and shock,
temperature, humidity and inclination indicators. Such devices are
desirable to track articles to be shipped and/or to monitor the
condition of the articles during shipping or storage. From various
accidental and intentional causes, shipping monitoring instruments
have a tendency to be removed during shipping and storage.
Accordingly, it is desirable to place shipping monitoring
instruments in locations where they will be protected from damage
and tampering. However, it is also desirable that the shipping
monitoring be readily readable and/or recoverable by authorized
personnel.
[0051] The nested panel structure of the support legs 12, and the
mating of the foldable support legs 12 with the pallet deck 14
afford excellent opportunities for optimal placement of shipping
monitoring instruments. For example, a shipping monitoring
instrument can be placed on the top panel 28 (see the location 180
indicated in FIG. 7). When the support leg 12 is then mated to the
pallet deck 14 (see the location 180 indicated in FIG. 1), the
shipping monitoring instrument is protected from physical damage
and concealed from prospective tamperers.
[0052] The foregoing is not an exhaustive list of modifications,
variations, or adaptations to particular circumstances that can be
made within the scope of the present invention. Rather, those
skilled in the art will discern that these and other variations,
modifications and adaptations to particular circumstances fall
within the scope of the invention as herein shown and
described.
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