U.S. patent application number 12/510055 was filed with the patent office on 2010-01-21 for cardboard pallet.
Invention is credited to Garland Gee, Randall Harp.
Application Number | 20100011999 12/510055 |
Document ID | / |
Family ID | 41529131 |
Filed Date | 2010-01-21 |
United States Patent
Application |
20100011999 |
Kind Code |
A1 |
Harp; Randall ; et
al. |
January 21, 2010 |
CARDBOARD PALLET
Abstract
A cardboard pallet that offers improved strength, stiffness,
durability, weight, and cost-effectiveness over cardboard pallets
of the prior art is disclosed. The pallet consists of a top deck,
internal cylindrical, triangular and hexagonal cores, side walls,
and a bottom deck. The top sheet of cardboard is shaped in the form
of an octagon and rests on internal triangular and hexagonal cores.
The bottom sheet of cardboard is used to construct the side walls
and bottom deck, and the bottom sheet of cardboard also has flaps
that secure the bottom deck and sides to the top deck. The bottom
deck has four holes for a pallet truck; the cardboard which is cut
out to form the pallet truck holes are scored such that the cut out
portions can form reinforcing tubular cores. The sides have
openings that allow entry from four directions by a mechanized
pallet handler.
Inventors: |
Harp; Randall; (Springdale,
AR) ; Gee; Garland; (Russellville, AR) |
Correspondence
Address: |
HENRY LAW FIRM;Henry Mark Murphey
P.O. BOX 8850
FAYETTEVILLE
AR
72703
US
|
Family ID: |
41529131 |
Appl. No.: |
12/510055 |
Filed: |
July 27, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11452589 |
Jun 14, 2006 |
|
|
|
12510055 |
|
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Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 2519/00562
20130101; B65D 2519/00019 20130101; B65D 2519/00288 20130101; B65D
2519/00124 20130101; B65D 2519/00273 20130101; B65D 2519/00432
20130101; B65D 2519/00318 20130101; B65D 2519/00054 20130101; B65D
2519/00343 20130101; B65D 19/0012 20130101 |
Class at
Publication: |
108/51.3 |
International
Class: |
B65D 19/00 20060101
B65D019/00 |
Claims
1. An octagonal cardboard pallet designed to allow for multiple
internal support members, said pallet having at least eight
openings that allow pallet-handling machine entry from four
directions, comprising: A bottom sheet forming a bottom deck,
having not less than eight tabs with first tab score lines such
that the tabs can be folded along the first tab score lines to form
at least eight side walls that are substantially perpendicular to
the bottom deck, said tabs also having second tab score lines such
that the tabs can be folded along the second tab score lines to
form one or more adhesive connection surface(s); At least five
internal cores having at least six sides which communicate with and
are secured to the bottom deck; At least four internal triangular
cores having not more than three sides which communicate with and
are secured to the bottom deck; At least nine internal cylindrical
cores which communicate with and are secured to the bottom deck; At
least four rectangular openings cut into the bottom sheet and which
are spaced equidistant from one another; and, A top sheet forming a
top deck having the same octagonal shape as the bottom deck, which
is aligned with the bottom deck and secured with adhesive to the
hexagonal, triangular, and cylindrical cores, as well as the
adhesive connection surfaces.
2. The cardboard pallet of claim 1, further comprising the
application of a water resistant sealant to the cardboard
pallet.
3. The cardboard pallet of claim 1, wherein the eight openings that
allow pallet-handling machine entry from four directions are
created by cutting a U-shaped design into the tabs to create an
opening whereby the remaining cardboard may pivot upward along a
score line to serve as an additional adhesive surface with which to
connect the top sheet.
Description
CROSS REFERENCES
[0001] Continuation in Part of application Ser. No. 11/452,589
filed Jun. 14, 2006.
GOVERNMENTAL RIGHTS
[0002] None.
BACKGROUND OF THE INVENTION
[0003] Pallets are necessary to virtually all manufacturing and
retail industries. Indeed, a global materials-handling industry
relies exclusively on pallets to distribute goods from
manufacturing sources to the ultimate purchaser. Products are now
shipped on pallets that are capable of being moved by automated
systems, by forklift in warehouse settings, or by pallet truck in
retail settings. Pallets are available in a wide range of sizes and
grades, and the design of a pallet is a function of at least five
parameters, including strength, stiffness, durability,
functionality, and price.
[0004] Traditional pallets are constructed of wood, as wood strikes
a reasonable balance between the five pallet parameters. However,
once wood pallets reach the end of their useful lives, they must be
destroyed by pollution-emitting incineration or recycled into some
other wood-based product. Wood pallets have other disadvantages,
such as fasteners that are capable of damaging products, splinters,
warping due to high initial moisture content, susceptibility to
pest infestation, and high manufacturing tolerances that lead to
wide variations in actual pallet size. Wood pallets still account
for at least 90% of the 1.9 billion pallets in circulation in the
United States.
[0005] More recently, paper-based pallets constructed from
corrugated cardboard have begun to increase market pressure despite
the fact that wood pallets are generally less expensive and more
durable than typical cardboard pallets. The advantages of using
paper materials for constructing pallets include lower weight than
wood pallets and the ability to easily recycle the pallet once it
reaches the end of its useful life. Cardboard pallets also offer
the benefits of flat decks, resistance to insect damage, and low
moisture content.
[0006] However, cardboard pallets of the prior art were not without
disadvantages. When compared to wood pallets, cardboard pallets of
the prior art were lacking in the parameters of strength,
stiffness, and durability, which resulted in a low adoption rate in
the materials-handling industry. To a large extent, the inadequacy
of cardboard pallets in these areas was linked to inferior designs
that lacked reinforcements at appropriate stress points on the
pallet. For example, cardboard pallets are susceptible to damage by
forklift and pallet truck operators when the tangs of the
mechanized pallet handler do not enter the cardboard pallet
properly. It is thus one object of the present invention to provide
a cardboard pallet that is reinforced at entry points for
mechanized pallet handlers.
[0007] One solution found in the prior art to address the
insufficient strength, stiffness, and durability of cardboard
pallets was to combine cardboard with traditional wood materials.
For instance, U.S. Pat. No. 4,378,743 (the "'743 patent") discloses
a cardboard pallet that utilizes wood runners to purportedly
increase strength and durability traditionally considered lacking
in cardboard pallets. However, the use of wood in the '743 patent
subjects it to the same criticisms of an all-wood pallet, such as
weight, moisture damage to the cardboard, susceptibility to insect
damage, and fastener-caused damage to the load. It is thus an
object of the present invention to provide a cardboard pallet that
provides strength, stiffness, and durability without incorporating
traditional wood materials.
[0008] Cardboard pallets of the prior art also lacked sufficient
strength and stiffness at the pallets' side walls. For instance,
U.S. Pat. Nos. 4,085,847 (the "'847 patent") and 6,070,726 (the
"'726 patent") disclose tray-type cardboard pallets whose side
walls are comprised of overlapping cardboard flaps that are glued
together. This design is believed to be deficient because it is
susceptible to damage by a force applied to the interior of the
pallet's side, such as a sudden lateral movement of the load or an
impact by a misguided mechanized pallet handler tang. The '847 and
'726 patents also disclose a method of installing a top deck on the
patent, but these designs are easily compromised as both rely upon
a top deck that simply rests on top of internal support structures.
The design of the '847 and '726 patents lack the essential feature
of securing the top deck to the sides of the pallet, and if the
prior designs had included such feature then the resulting pallets
would have had stronger sides and a stronger deck. It is thus a
further objection of the present invention to provide a cardboard
pallet that has sides that are less susceptible to damage caused by
forces applied to the interior of the pallet's side walls and that
secures the top deck to the sides of the pallet.
[0009] Still another method of increasing the strength, stiffness,
and durability of cardboard pallets involves using many layers of
cardboard to provide added strength. For example, U.S. Pat. No.
5,465,672 (the "'672 patent") discloses a pallet that has four
cardboard layers. The '672 patent serves as an inelegant solution
to the problem posed by the lack of strength, stiffness, and
durability in cardboard pallets of the prior art, as the amount of
cardboard used detracts from the primary advantage of a cardboard
pallet of low weight. The amount of cardboard used in the '672
patent also renders it essentially unmarketable due to the even
higher cost of construction than a typical cardboard pallet and the
current low cost of wood pallets. It is thus an object of the
present invention to provide a cardboard pallet that substantially
requires only a top and bottom layer.
[0010] As shown by the deficiencies of the prior art discussed
above, there is a need in the materials handling industry for a
cardboard pallet that offers strength, stiffness, durability, and
price that rivals that of a wood pallet. It is thus an object of
the present invention to provide a strong, stiff, durable,
cost-effective, and recyclable cardboard pallet.
[0011] The apparatus in accordance with the present invention
provides an internally-reinforced cardboard pallet that conserves
construction materials, provides commercially acceptable strength,
load bearing capabilities, stiffness, and durability, and is easily
constructed at a commercially reasonable cost.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention provides a two-layer,
internally-reinforced, four-way accessible cardboard pallet that
utilizes unique hexagonal internal cores to provide commercially
adequate strength, stiffness, and durability. The hexagonal cores
provide an advantage over the square internal cores set forth by
the prior art, as the hexagonal cores provide more strength and
rigidity to the pallet. Hexagonal cores also increase the stiffness
of the cardboard pallet, as hexagonal cores are less susceptible to
shear forces than rectangular cores; that is, a rectangular core
deforms far more easily than a hexagonal core when a force is
applied to the long side of the core. The hexagonal cores also
provide an advantage in strength and design in that a misguided
mechanized pallet handler tang that impacts the core does not
strike a corner of the hexagonal core, but is more likely
redirected off a face of the hexagonal core. Further, even if one
corner of the hexagonal core is compromised, the hexagonal core has
more support corners available to continue supporting the pallet
structure.
[0013] The top deck of the cardboard pallet is essentially a solid
octagon of cardboard. The original starting medium forming the
bottom deck of the cardboard pallet has a plurality of scores that
allows it to be folded into what eventually becomes the octagonal
bottom deck, side walls, and flaps that overlap the top deck.
Triangular and hexagonal cores are secured to the bottom deck, and
the top deck is secured on top of the cores. Then, the flaps are
secured to the top deck. Each of four side walls of the pallet are
pre-scored and pre-cut such that two openings are made for
mechanized pallet handler tangs by folding a reinforcing flap up
into the interior of the pallet and securing it to the bottom of
the top deck.
[0014] The first preferred embodiment is not a regular octagon.
That is, two of the four side walls of the pallet having the
openings are not wide enough to accommodate a standard mechanized
pallet handler tang opening. Therefore, the remaining four side
walls are notched to create a uniform mechanized pallet handler
tang opening from all four directions. Like the opening itself, the
notch is also formed by folding a reinforcing flap up into the
interior of the pallet and securing it to the bottom of the top
deck.
[0015] The bottom deck preferentially has four openings designed to
allow the wheels of a pallet truck to make contact with the floor.
Each of the cutouts forming the four openings for pallet truck
wheels is preferentially scored such that the excess material from
the cutout can be used as construction material for tubular cores.
The tubular cores are designed to be inserted within the interior
of the triangular and hexagonal cores or at mechanized pallet
handler tang entry points, which serves to strengthen and stiffen
the cardboard pallet.
[0016] The second preferred embodiment lacks notched side walls.
That is, four side have walls with openings for mechanized pallet
handler tangs, while the remaining four sides have no walls. The
second preferred embodiment utilizes tubular cores created from the
pallet truck wheel cutouts instead of triangular cores to support
and strengthen the top deck. The second preferred embodiment is
intended for use in applications requiring lower strength or less
weight.
[0017] Optionally, a water resistant sealant can be applied to the
cardboard pallet to protect from moisture damage. The sealant is
preferably applied in a light coat to keep the total weight of the
cardboard pallet down and to allow the treated cardboard pallet to
still be recycled.
[0018] These and other advantages will become apparent from the
following detailed description which, when viewed in light of the
accompanying drawings, disclose the embodiments of the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a perspective view of the first preferred
embodiment of the present invention.
[0020] FIG. 2 is a schematic view of the bottom cardboard sheet
that forms the bottom deck, sides, and flaps of the present
invention.
[0021] FIG. 3 is a perspective view of a triangular core of the
present invention.
[0022] FIG. 4 is a perspective view of a hexagonal core of the
present invention.
[0023] FIG. 5 is an exploded perspective view of the cardboard
pallet of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to FIGS. 1-5, the cardboard pallet 101 of the
present invention is preferably constructed using a die cutting
tool programmed to use schematics to score and cut the bottom sheet
201, triangular cores 301, hexagonal cores 401, and top deck 501
with precision. The components are then assembled by hand or by
machine and secured into place.
[0025] Referring now to FIG. 2, bottom sheet 201 is cut from an
original starting medium sheet of cardboard. Bottom sheet 201 is
comprised of an octagonal bottom deck 203, two first tabs 205, two
second tabs 207, and four third tabs 209. First tabs 205 are
further comprised of first tab score lines 211, first tab opening
cut lines 213, first tab reinforcement score lines 215, and first
tab flap score lines 217. Second tabs 207 are further comprised of
second tab score lines 219, second tab opening cut lines 221,
second tab reinforcement score lines 223, and second tab flap score
lines 225. Third tabs 207 may be further comprised of third tab
score lines 227, third tab opening cut lines 229, third tab
reinforcement score lines 231, and third tab flap score lines
233.
[0026] To construct the pallet, a plurality of hexagonal cores 401
are glued into a plurality of first tab hexagonal core positions
235 adjacent to first tabs 205 and a plurality of second tab
hexagonal core positions 237 adjacent to second tabs 207. A
hexagonal core 401 is also glued into center hexagonal core
position 239. A plurality of triangular cores 301 are glued into a
plurality of triangular core positions 241 adjacent to third tabs
209.
[0027] After the cores are secured into place, top deck 501 is
aligned with bottom deck 202 and glued to triangular cores 301 and
hexagonal cores 401. First tabs 205 are folded along first tab
score lines 211 and glued to adjacent hexagonal cores 401 and the
thin edge of top deck 501, which forms a plurality of first side
walls 243. Second tabs 207 are folded along second tab score lines
219 and glued to adjacent hexagonal cores 401 and the thin edge of
top deck 501, which forms a plurality of second side walls 245.
Third tabs 207 may be folded along third tab score lines 227 and
glued to adjacent triangular cores 301 and the thin edge of top
deck 501, which forms a plurality of third side walls 247.
[0028] Once side walls 243, 245, and 247 are constructed, first
tabs 205 are folded along first tab flap score lines 217 to form
first tab flaps 249. First tab flaps 249 are glued to the top of
top deck 501. Second tabs 207 are folded along second tab flap
score lines 225 to form second tab flaps 251. Second tab flaps 251
are glued to the top of top deck 501. Third tabs 207 are folded
along third tab flap score lines 233 to form third tab flaps 253.
Third tab flaps 253 are glued to the top of top deck 501.
[0029] After top deck 501 is secured to tab flaps 249, 251, and
253, first tabs 205 are folded along first tab reinforcement score
lines 215 to form first tab reinforcements 255. First tab
reinforcements 255 are glued to the bottom of top deck 501. Second
tabs 207 are folded along second tab reinforcement score lines 223
to form second tab reinforcements 257. Second tab reinforcements
257 are glued to the bottom of top deck 501. Third tabs 207 are
folded along third tab reinforcement score lines 231 to form third
tab reinforcements 259. Third tab reinforcements 259 may be glued
to the bottom of top deck 501. When tab reinforcements 255, 257,
and 259 are folded and secured into place, mechanized pallet
handler tang openings 103 become visible.
[0030] Optionally, bottom deck 207 allows passage of the wheels of
a pallet truck with a plurality of pallet truck cutouts 261, which
are formed by pallet truck cutout cut lines 263. Pallet truck
cutouts 261 are scored along pallet truck cutout score lines 265
such that the pallet truck cutouts 261 can be folded into tubular
cores 503, shown in FIG. 5. Tubular cores 503 are glued to top deck
501 or bottom deck 203 at mechanized pallet handler tang entry
points 267, 269, 271, and/or 273 or in the interior 275 of
triangular cores 301 or hexagonal cores 401. Regardless of where
tubular cores 503 are positioned, tubular cores 503 serve to
strengthen and stiffen cardboard pallet 101, which in turn
increases the durability of cardboard pallet 101.
[0031] The first preferred embodiment of the present invention
forms a non-regular octagon. In the first preferred embodiment,
first tab hexagonal core positions 235 are placed such that a flat
side of hexagonal cores 401 communicates with first side walls 243,
while second tab hexagonal core positions 237 are placed such that
only a single vertex of hexagonal cores 401 communicates with
second side walls 245.
[0032] Optionally, the cardboard pallet 101 of the present
invention can form a regular octagon. In the regular octagon
embodiment, first side tabs 203 and second side tabs 205 are
identical. Hexagonal core positions 235 and 237 are placed such
that only a single vertex of hexagonal cores 401 communicates with
first side walls 243 and second side walls 245.
[0033] The second preferred embodiment lacks third tabs 207, which
lowers overall weight and reduces the amount of starting material
required to construct cardboard pallet 101 with greatly sacrificing
strength. The second preferred embodiment utilizes a plurality of
hexagonal cores 401 but not triangular cores 301. Instead of
triangular cores 301, the second preferred embodiment uses a
plurality of tubular cores 503 inserted at in what would be the
interior 275 of triangular cores 301 were triangular cores 301 used
in the second preferred embodiment. Optionally, two or more tubular
cores 501 can be placed substantially along the path marked by
triangular core positions 241.
[0034] In accordance with the present invention, a cardboard pallet
provides improved strength, stiffness, and durability while
weighing less and creating less excess materials. However, it
should be clear that the present invention is not to be construed
as limited to the forms shown, which are to be considered
illustrative rather than restrictive.
* * * * *