U.S. patent application number 12/826070 was filed with the patent office on 2011-06-09 for pallet structure with protective shell.
This patent application is currently assigned to Pregis Innovative Packaging, Inc.. Invention is credited to Lawrence James French, Robert E. Jaegers.
Application Number | 20110132238 12/826070 |
Document ID | / |
Family ID | 44080724 |
Filed Date | 2011-06-09 |
United States Patent
Application |
20110132238 |
Kind Code |
A1 |
Jaegers; Robert E. ; et
al. |
June 9, 2011 |
Pallet Structure with Protective Shell
Abstract
A pallet structure having a deck having an upper surface that
can hold or bear a load, a first runner core below the deck, and a
shell of sheet material that can cover a portion of a surface of
the first runner core or deck, wherein the shell comprises a
material that provides a higher impact resistance than the material
comprising the first runner core or deck covered by the shell.
Inventors: |
Jaegers; Robert E.; (Lake
Zurich, IL) ; French; Lawrence James; (Wallingford,
CT) |
Assignee: |
Pregis Innovative Packaging,
Inc.
Deerfield
IL
|
Family ID: |
44080724 |
Appl. No.: |
12/826070 |
Filed: |
June 29, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61267771 |
Dec 8, 2009 |
|
|
|
Current U.S.
Class: |
108/55.1 ;
108/51.11; 108/57.34 |
Current CPC
Class: |
B65D 19/0026 20130101;
B65D 2519/00432 20130101; B65D 2519/00562 20130101; B65D 2519/00303
20130101; B65D 2519/00019 20130101; B65D 2519/00054 20130101; B65D
2519/00358 20130101; B65D 2519/00273 20130101; B65D 2519/00124
20130101; B65D 2519/00323 20130101; B65D 2519/00333 20130101; B65D
2519/00288 20130101 |
Class at
Publication: |
108/55.1 ;
108/51.11; 108/57.34 |
International
Class: |
B65D 19/02 20060101
B65D019/02; B65D 19/38 20060101 B65D019/38 |
Claims
1. A pallet structure, comprising: a deck having an upper surface
configured to hold a load bearing; a first runner core associated
with and disposed below the deck; and a shell of sheet material
covering a portion of a surface of the first runner core or deck,
wherein the shell comprises a material that provides a higher
impact resistance than the material comprising the first runner
core or deck covered by the shell.
2. The pallet structure of claim 1, wherein the shell comprises a
multi-ply sheet material.
3. The pallet structure of claim 2, where the deck comprises a
low-density core and high-density facing, and an outer layer of the
shell extends onto and is bonded to the deck facing and is made of
a same sheet material as the facing.
4. The pallet structure of claim 1, wherein the deck further
comprises an edge portion, and the shell covers a lateral edge
surface of the edge portion of the deck.
5. The pallet structure of claim 4, wherein the shell extends from
the lateral edge surface of the edge portion of the deck around the
first runner core to a bottom surface portion of the deck on an
opposite lateral side of the first runner core to protect the deck
and first runner core to improve attachment of the first runner
core to the deck.
6. The pallet structure of claim 5, wherein: the deck has an edge
portion displaced laterally outward from the first runner core and
that includes the lateral edge surface of the edge portion of the
deck, and the shell extends between the lateral edge surface of the
edge portion of the deck and first runner core to cover a bottom
surface of the edge portion of the deck.
7. The pallet structure of claim 6, wherein the shell further
covers an upper surface of the edge portion of the deck.
8. The pallet structure of claim 1, further comprising a second
runner core located at approximately a first end of the deck
portion, wherein: the deck further comprises a second edge portion
opposite the first edge portion, and the shell covers a lateral
edge surface of the second edge portion of the deck; the shell
extends from the lateral edge surface of the second edge portion of
the deck around the second runner core to a bottom surface portion
of the deck on an opposite lateral side of the second runner core
to protect the deck and second runner core to improve attachment of
the second runner core to the deck.
9. The pallet structure of claim 1, wherein the sheet material of
the shell has a significantly greater density than the first runner
core.
10. The pallet structure of claim 9, wherein deck or first runner
core covered by the shell comprises a honeycomb paper material, and
the shell comprises a laminate paper material.
11. The pallet structure of claim 10, wherein the first runner core
comprises a material having more than 70% airspace, and the shell
comprises a material having less than 10% airspace.
12. A pallet structure, comprising: a first runner core having a
first lateral surface; a deck associated with and disposed above
the first runner core, the deck comprising an upper surface
configured to hold a load and an edge portion that extends past the
first lateral surface of the first runner core; and a shell of
sheet material covering a portion of an upper surface of the edge
portion of the deck, a portion of a first lateral surface of the
edge portion of the deck, a portion of a bottom surface of the edge
portion of the deck, and a portion of the first lateral surface of
the runner core.
13. The pallet structure of claim 12, wherein the shell further
covers a portion of a lower surface and a second lateral surface
disposed opposite the first lateral surface of the first runner
core.
14. The pallet structure of claim 12, wherein the sheet material of
the shell comprises has sufficiently greater density and toughness
than the first runner core to improve an impact resistance of the
covered portions.
15. The pallet structure of claim 12, wherein the shell material
disposed covering the portion of the upper surface of the edge
portion of the deck is thinner than the shell material covering at
least one of the other covered portions.
16. A pallet structure, comprising: a first runner core having a
first lateral surface; a deck associated with and disposed above
the first runner core and comprising an edge portion that extends
past the first lateral surface of the first runner core, the edge
portion having an upper surface and a first lateral surface; and a
shell of sheet material having a first shell portion covering at
least a portion of the upper surface of the edge portion of the
deck, and a second shell portion covering a portion of the first
lateral surface of the edge portion of the deck, wherein the second
shell portion has a greater thickness than at least part of the
first portion for minimizing a height of the shell on the upper
surface of the deck.
17. The pallet structure of claim 16, wherein the shell further
covers at least a portion of a bottom surface of the edge portion
of the deck.
18. The pallet structure of claim 17, wherein the shell comprises a
sheet material of sufficiently greater density than the material of
the deck edge portion to significantly improve an impact resistance
of the edge portion.
19. The pallet structure of claim 16, wherein the shell is made of
a multi-ply sheet material, and the at least part of the first
shell portion comprises fewer plies than the second shell
portion.
20. The pallet structure of claim 19, wherein the shell comprises a
ply that extends along the first and second shell portions, and
another ply that does not extend onto the at least part of the
first shell portion.
21. The pallet structure of claim 19, wherein the at least part of
the first shell portion comprises the entire portion of the shell
disposed on the upper surface of the deck.
22. The pallet structure of claim 19, wherein part of the second
shell portion adjacent and extending to the first shell portion
comprises fewer plies than another part of the second shell portion
that is spaced from the upper surface of the deck.
23. The pallet structure of claim 16, wherein the first runner core
further comprises at least one cutout portion.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application relates to and claims priority from U.S.
Patent Application Ser. No. 61/267,771 filed Dec. 8, 2009, the
entire disclosure of which is hereby incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a pallet structure having
a protective shell that can be used for the load-carrying support
of goods.
BACKGROUND
[0003] A pallet is a portable, horizontal, rigid platform used as a
base for assembling, storage, stacking, handling and transporting
goods as a unit load, often equipped with a superstructure.
Conventional pallets are generally constructed of wood made by
joining together a set of top and bottom deckboards fastened by
nails or staples to a continuous, solid board often called a
stringer or stringerboard. The pallet may have openings in the
design to accompany fork truck or hand jack equipment to insert
their forks between the top deck and bottom deck to lift the pallet
and its load off the floor. Pallets are generally square or
rectangle with two-way or four-way entry into the pallet. A typical
pallet size can be 48 inches by 40 inches, i.e., a 48 inch stringer
or a stringerboard and a 40 inch deckboard.
[0004] Labor and material costs involved in producing wooden
pallets are relatively high; and, as a result of these high costs,
wooden pallets are often required to be reused either by the
receiver or returned to the supplier which results in higher
shipping costs (normally they are returned to the supplier empty).
Wood pallets also weigh on the average forty (40) pounds, which
adds to the cost of shipping the load. Likewise due to the weight
of the wooden pallet the operator may have difficulty manually
moving the pallets. The repair or disposal of damaged wood pallets
adds to their cost. In some industries the typical wooden pallet is
used on an average of no more than twice before it must be replaced
or repaired.
[0005] Materials other than wood may be used in the design and
manufacture of pallets such as metal, plastic, and paper. The use
of paper materials can be cost competitive to materials such as
wood, metal, and plastic, while at the same time offering benefits
that are not available through the use of traditional wood
materials. The benefits of using paper materials are several fold.
Paper products are lighter than wood, plastic, or metal products,
and when formed into a honeycomb structure may have remarkable
strength. Paper pallets have been made, for example, of glued paper
honeycomb and of paper corrugate and held together with glue.
[0006] Paper products can be made biodegradable to allow for
disposal without penalty charges or prohibitions from land fills or
they can be baled and recycled to paper companies. Because of the
ease of working with paper materials and the availability of
various honeycomb structures, products can be manufactured in a
variety of shapes and sizes to meet any particular
requirements.
[0007] Pallets that are made of a lightweight, paper material,
however, are more likely to crush when, e.g., picked up at the
wrong spot by a fork truck or hand jack equipment, or when hit or
pushed at side surfaces of the paper pallet.
SUMMARY
[0008] In one embodiment, a pallet structure is provided with a
deck that has an upper surface configured to hold a load bearing. A
first runner core is preferably provided below the deck, with a
shell, such as of sheet material, covering a portion of a surface
of the first runner core or deck. The preferred shell is made of a
material that provides a higher impact resistance than the material
comprising the first runner core or deck covered by the shell.
[0009] The shell can comprise a multi-layered sheet material, such
as a multi-ply material, and at least one of the first runner core
or deck can comprise a sheet material. The deck can comprise an
edge portion, and the shell can cover a lateral edge surface of the
edge portion of the deck. In some embodiments, the shell extends
from the lateral edge surface of the edge portion of the deck
around the first runner core to a bottom surface portion of the
deck on an opposite lateral side of the first runner core to
protect the deck and first runner core to improve attachment of the
first runner core to the deck.
[0010] The deck can have an edge portion displaced laterally
outward from the first runner core and that includes the lateral
edge surface of the edge portion of the deck, and the shell can
extend between the lateral edge surface of the edge portion of the
deck and first runner core to cover a bottom surface of the edge
portion of the deck. The shell can further cover an upper surface
of the edge portion of the deck.
[0011] The pallet structure can include additional runners, for
example having a second runner core located at approximately a
first end of the deck portion, with the deck including a second
edge portion opposite the first edge portion, and the shell
covering a lateral edge surface of the second edge portion of the
deck. The shell can extend from the lateral edge surface of the
second edge portion of the deck around the second runner core to a
bottom surface portion of the deck on an opposite lateral side of
the second runner core to protect the deck and second runner core
to improve attachment of the second runner core to the deck.
[0012] In some embodiments, the shell can comprise a sheet material
of a significantly greater density than the first runner core. The
deck or first runner core covered by the shell can comprise a
honeycomb paper material, and the shell can comprise a laminate
paper material. The first runner core can comprise, for example, a
material having more than 70% airspace, and the shell comprises a
material having less than 10% airspace.
[0013] In certain embodiments, the deck has an upper surface
configured to hold a load and an edge portion that extends past the
first lateral surface of the first runner core, and the shell
covers a portion of an upper surface of the edge portion of the
deck, a portion of a first lateral surface of the edge portion of
the deck, a portion of a bottom surface of the edge portion of the
deck, and a portion of the first lateral surface of the runner
core. The shell can further cover a portion of a lower surface and
a second lateral surface disposed opposite the first lateral
surface of the first runner core. As indicated above, the shell can
comprise a sheet material of a sufficiently greater density and
toughness than the first runner core to improve an impact
resistance of the covered portions. The runner core may have a
cutout portion therethrough on a lateral surface.
[0014] The shell material covering the portion of the upper surface
of the edge portion of the deck can be thinner than the shell
material covering at least one of the other covered portions the
shell. The shell can have a first shell portion 67 covering at
least a portion of the upper surface of the edge portion of the
deck, and a second shell portion 68 covering a portion of the first
lateral surface of the edge portion of the deck, with the second
shell portion having a greater thickness than at least part of the
first portion for minimizing a height of the shell on the upper
surface of the deck.
[0015] The shell can be made of a multi-ply sheet material, and,
for instance, part or all of the first shell portion can have fewer
plies than the second shell portion. The shell can comprise a ply
that extends along the first and second shell portions, and another
ply that does not extend onto the at least part of the first shell
portion. The at least part of the first shell portion can comprise
the entire portion of the shell disposed on the upper surface of
the deck. Part of the second shell portion adjacent and extending
to the first shell portion can comprise fewer plies than another
part of the second shell portion that is spaced from the upper
surface of the deck.
BRIEF DESCRIPTION OF FIGURES
[0016] FIG. 1a shows a perspective view of a pallet structure
according to an embodiment;
[0017] FIG. 1b shows a side perspective view of the pallet
structure of the embodiment of FIG. 1a.
[0018] FIG. 1c shows a cut-away side view of the pallet structure
of FIG. 1c.
[0019] FIG. 2 shows a perspective view of a deck and a runner
according to certain embodiments;
[0020] FIG. 3 shows a perspective view of a middle runner of a
pallet structure according to certain embodiments;
[0021] FIG. 4 shows a perspective view of a deck and a runner
according to the embodiment of FIG. 1a;
[0022] FIG. 5 shows a top cross-sectional view of a runner core
taken along plane V-V of FIG. 4; and
[0023] FIG. 6 shows a perspective view of a corner of a pallet
structure constructed according to another embodiment.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1a, a pallet structure 100 is shown having
a deck 10 and runners 200, 300 and 400. Two or more runners may be
provided, and in preferred embodiments 3 runners may be provided.
Two runners 200, 400 may be provided on opposite ends of the pallet
structure 100, and a middle runner 300 along a middle portion of
the pallet structure 100. Each runner 200, 300, 400 can comprise a
shell 50 enclosing a runner support member or interior structure,
such as a core 20, 30, 40, respectively. Each runner core 20, 30
and 40 can comprise a relatively low-density material, which in
some embodiments may be a honeycomb structure. The deck 10 can
comprise a top facing 11 and a bottom facing 12, which may be made
of a relatively high-density material, with a honeycomb core 13
between the top facing 11 and bottom facing 12. The majority of the
top facing 11 of the deck can be free of the shell (i.e., not
covered by the shell 50) and preferably exposed as an outer
surface, as shown in FIG. 1a. The top facing 11, bottom facing 12,
and honeycomb structure 13 can comprise a relatively high-density
paper sheet material, such as solid sheet material with essentially
no airspaces. Although the pallet structure 100 shown in FIG. 1a
has a deck 10 and runners 200, 300, and 400 with lateral side
surfaces that are substantially vertical, and the top and bottom
sides thereof are substantially horizontal, other embodiments can
provide for these surfaces to have an angular orientation depending
on the needs of the pallet structure.
[0025] With reference to the material of the facings and the core,
the facings may be made of a paper material. The paper material may
be a multilayered sheet material. The paper material may have a
density between approximately 26 lb./1000 sq. ft.-90 lb./sq. ft.
The core may be a honeycomb material. The honeycomb core may be
made of a material having more than 60% airspace, and the first
facing may comprise a material having less than 25% airspace. For
example, the panels can comprise a material having over 60%, 70%,
or 90% airspace, although any amount of airspace may be acceptable.
In other embodiments, a corrugated or other low-density structure
may be used in place of the honeycomb structure The facings may
generally have a significantly greater density than the
low-density-core. In some embodiments, the facings can be made with
a material having less than 25% airspace, and preferably less than
10% airspace. Examples of the density of the facings are between 26
lb./1000 sq. ft. and 90 lb./sq. ft., and preferably about 56
lb./1000 sq. ft. The facings are preferably made of a single sheet
of material, but may be made of multiple plies, for instance.
[0026] The runners 200, 300 and 400 can be interrupted along the
length of the runners, providing cutouts, spaces, or holes between
sections of the runners, as depicted in FIG. 1b (reference numeral
91), to receive a forklift from another angle, such as from the
lateral sides of the pallet structure 100, so that the pallet
structure can be lifted from the front, back or sides. The pallet
structure 100 can have spaces 90 along the bottom portion of the
deck 10 between runners 200 and 300, and runners 300 and 400, as
seen in FIG. 1a. Accordingly, a shell 50 is not required in this
area in some embodiments, and savings can be attained by not using
a shell 50 in this area. In alternative embodiments, a shell 50 may
be provided along the entire bottom surface of the deck 10, along
with the runner cores 20, 30 and 40. In these embodiments, the
shell 50 is continuous along the entire bottom surface of the deck,
as shown in FIG. 1c. In particular, reference numeral 92 depicts
the portion of the shell above which the runner interior has been
removed to allow for a forklift to enter. In some embodiments, the
spaces 91 of the runners may be of a height which is less than the
height of the runner, for example, the spaces may only be the
height of one layer of the core of the runner. As depicted in FIG.
1c, the runner has one continuous core layer 94, and one
discontinuous core structure layer 93, wherein the spaces 91 are
located. The edges 97 define the ends of the discontinuous core
layer 93. The width of spaces 91, defined by opposite ends 97, may
be approximately 1-15 inches, more preferably 2-10 inches, and most
preferable 6-9 inches.
[0027] Referring now to FIG. 2, a runner 200 along an end portion
of the deck 10 is shown having a runner core 20 and a protective
shell 50. The runner core 20 can comprise one or more layers of
sheet material. In the embodiment shown in FIG. 2, three layers 22,
25 and 28 are provided. A top layer 22 has a top facing 21 and a
bottom facing 23, a middle layer 25 has a top facing 24 and a
bottom facing 26, and a bottom layer 28 has a top facing 27 and a
bottom facing 29. The layers 22, 25 and 28 can comprise a honeycomb
structure. The top facing 27 of the bottom layer 28 can be
associated with or adhered to the bottom facing 26 of the middle
layer 25, and the top facing 24 of the middle layer 25 can be
associated with or adhered to the bottom facing 23 of the top layer
22. The top facing 21 of the top layer 22 can be associated with or
adhered to the bottom sheet 12 of the deck 10. The top and bottom
facings can be made of a paper sheeting material. Of course, more
or less layers can be provided in the runners, depending on the
needs of the pallet structure 100, such as size of the pallet
structure, the weight of the load placed upon the pallet structure,
etc.
[0028] The walls 60 of the layers 22, 25 and 28 can have a vertical
orientation as shown in FIG. 2. Alternatively, the walls 60 can
have a non-vertical or horizontal orientation, or have an angular
orientation. Each layer can have a similar or substantially similar
height, or have different heights. For example, the height h2 of
layer 25 can be greater than the height h1 of layer 22 and height
h3 of layer 28. In some embodiments, the height of all 3 or more
layers can be the same, or can vary as required. The heights h1, h2
and h3 preferably can vary from 1/2 to 5 inches, and more
preferably between 1.5 and 4 inches, and most preferably between 2
and 3.5 inches, although it will be appreciated that any heights,
h1, h2, h3 may be used. Various adhesives can be used between the
layers to adhere the sheets between the layers to each other, as
well as to adhere the various parts of the pallet to each other,
such as, but not limited to PVA glue, EVA glue, water based
adhesives, starch based adhesives, HotMelt.RTM., and solventless
adhesives. Preferred embodiments may utilize PVA glue, especially
as between honeycomb walls 60. The thickness of the disclosed
facings may vary, for example, between 0.00788 inches in the case
of a 31 lb./1000 sq. ft. density layer, and 0.02728 inches in the
case of a 90 lb./1000 sq. ft. density layer. In preferred
embodiments, the thickness may vary linearly between 0.00788 inches
and 0.02728 inches for layer densities between 31 and 90 lb./sq.
ft., as the thickness may vary generally linearly in proportion to
density.
[0029] The panel or pallet structure of the preferred embodiment is
capable of handling loads up to about 2000, 2250, or 2500 lbs. All
portions of the panel or pallet structure, including the facings
and core, can be made of sheet material, such as paper material,
which can provide savings on shipping costs and can be recyclable
and biodegradable, and can provide a lightweight, low-cost
structure. Furthermore, the use of paper materials can be cost
competitive to materials such as wood, metal, and plastic, while at
the same time offering benefits that are not available through the
use of traditional wood materials. Paper products can be made
lighter than wood, plastic, or metal products, and when formed into
a honeycomb structure may have remarkable strength. Because of the
ease of working with paper materials and the availability of
various honeycomb structures, products can be manufactured in a
variety of shapes and sizes to meet any particular requirements.
Exemplary honeycomb panels which may be used with the present
disclosure include those which are produced under the Hexacomb.RTM.
brand by Pregis Corporation. Other embodiments of the panel
structure described above are also possible.
[0030] The runner cores 20, 30, 40 and honeycomb structure 13 of
the deck 10 can be configured to vertically support the weight of
the load that is supported on the deck. In the embodiment shown,
the honeycomb structure 13 of the deck 10 and runner 200, 300, 400
is sufficiently strong to withstand typical vertical forces
applied. This is assisted by the vertical orientation of the
honeycomb walls 60, and their association with each other at
non-parallel angles in the horizontal direction. For example,
vertical forces of at least 60 psi may be withstood in the case of
a 195 lb./1000 bd. ft. honeycomb structure of the deck 10 and cores
20, 30, and 40, although other embodiments may range from 30-80
psi. The honeycomb of the deck 10 and runner cores 20, 30, 40,
however, are typically more prone to crushing or puncturing due to
impacts, especially in a horizontal direction, or perpendicular to
the honeycomb walls 60, than the shell 50. For instance, exposed
portions of the honeycomb 13 or runner cores 20, 30, 40 may crumple
when exposed to a force or impact along the horizontal sides.
[0031] Accordingly, in exemplary embodiments, a shell 50 can be
provided along and to protect one or more surfaces of the deck 10
and/or runner core 20, which are preferably surfaces most prone to
impact, scraping, or other contact during handling, moving,
loading, and unloading, such as by a forklift, shelving, or the
product loaded thereon. For example, the shell 50 can be provided
at one or more peripheral, side edges of the runner core 20 and/or
of the deck 10. The shell 50 can be provided as a continuous sheet
extending along one or more of the bottom surface 52 of the runner
core 20, a first lateral surface 51 of the runner core 20 and a
second lateral surface 53 opposite the first lateral surface 51. In
the embodiment shown in FIG. 2, the shell 50 is provided on the
bottom surface 52, first lateral surface 51 and second lateral face
53. The shell 50 can extend from the first lateral surface 51 of
the edge portion 14 of the deck 10 around the first runner core 20
to a bottom surface portion 54 of the deck on an opposite lateral
side of the runner core 20 to protect the deck 10 and runner core
20 to improve attachment of the runner core 20 to the deck 10.
[0032] However, one of ordinary skill in the art would understand
that different surfaces can be protected. For example, it may be
important to protect the first lateral surface 51 of the runner
core 20 as any side impact will likely hit from that particular
side of the first lateral surface 51. The shell 50 may be provided
on the bottom surface 52 if the load is being lifted by a fork lift
or other mechanical means, which can apply a force in that
area.
[0033] The shell 50 can also be provided along a portion of a
bottom surface 55 of an edge portion 14 of the deck 10 adjacent the
first lateral surface 51 of the runner core 20. The shell 50 can
also be provided along a portion of a bottom surface 54 of the deck
10 adjacent the second lateral surface 53 of the runner core
20.
[0034] The shell 50 can preferably be made of a material that is
sufficiently tough and dense to protect the honeycomb or other such
structure of the runner and deck, which can be of a material such
as a paper material that can be less dense than the material of the
shell. Preferably, the shell material has an elevated density
compared to the structure of the deck and/or runner, as detailed
above. In one embodiment, the shell 50 can be made from a
multilayered sheet material. The sheet material can include
multiple layer or plies of paper. For example, double or triple ply
paper material can be used for the shell 50, that can have a
density greater than the interior of the runner 20 and/or deck 10.
This material is more dense that that of, e.g., the sheets that
comprise the interior of the layers 22, 25 and 28, and/or the top
and bottom facings of the layers, as outlined above. The shell 50
can provide much improved resistance to damage to the runners, and
especially the bottom surface 52 and first and second lateral
surfaces 51, 53 of the runner core 20. Such shell 50 is preferably
configured to provide resistance to, e.g., punctures, denting,
ripping, breaking the runner from the deck completely or partially,
crushing, impacts, etc., for the deck and/or runner of the pallet
structure 100. A similar shell can also be provided on the runner
core 40 on the opposite end of the deck 10, where the shell 50 can
cover the edge portion of the deck 10 on the opposite end of the
deck 10 as well, and one or more of the bottom, first and second
lateral surfaces of the runner core 40.
[0035] Referring now to FIG. 3, a middle runner 300 can be provided
comprising a runner core 30 can be provided along a bottom of
approximately a middle portion underneath a deck 10. The shell 50
can be made of similar materials as described above with reference
to FIG. 2. Further, the shell 50 can have supportive portions 34
and 35 that cover a portion of the bottom facing 12 of the deck 10.
These can typically be areas where a fork lift may be provided, and
thus, a shell 50 can protect these areas of the bottom of the deck
10. A top facing 36 of the top layer 37 of the runner core 30 can
be associated with or adhered to the bottom facing 12 of the deck
10. The shell 50 can also protect a first lateral surface 31 and
second lateral surface 33 of the runner core 30, and a bottom
surface 32 of the runner core 30.
[0036] Referring now to FIG. 4, which shows an edge portion 14 of
the deck 10 and runner 200 as shown in FIG. 1a, the shell 50 can
further be provided along an edge portion 14 of the deck 10. The
shell 50 can cover the runner core 20 similarly to as described
above with reference to FIG. 2. The shell 50 can further provide a
protective covering over a bottom surface 55 of the edge portion 14
(shell portion 65), an outer surface 56 of the edge portion 14
(shell portion 66), and a top surface 57 of the edge portion 14
(shell portion 67). A similar shell 50 can be provided along an
edge portion of the runner core 40 at the opposite end of the deck
10. This protective covering 50 can provide impact resistance for
the pallet structure 100 along the sides of the pallet structure
100. The portion of the shell 50 along the bottom surface 55, the
outer surface 56 and the top surface 57 of the edge portion 14 can
have single or multiple plies, such as single-ply, double-ply,
triple-ply, etc.
[0037] In one embodiment, the shell 50 along the bottom surface 55
and the outer surface 56 can have a greater thickness than the part
of the shell 50 disposed along the top surface 57 of the edge
portion 14. For example, the shell 50 along the bottom surface 55
and the outer surface 56 can be double-ply or triple-ply, and the
top surface 57 of the edge portion 14 can be single-ply. The
thickness x of the top surface 57 of the edge portion 14 can vary
from 0.001 inches to 0.5 inches, and may preferably be about 0.05,
0.1, 0.2, 0.3, or 0.4 inches. The thickness y of the shell 50 along
the bottom surface 55 and the outer surface 56 of the edge portion,
and the bottom surface 54 of the deck 10 can vary from 0.001 inches
to 0.5 inches, and may preferably be about 0.05, 0.1, 0.2, 0.3, or
0.4 inches. The thickness z of the shell 50 along the first lateral
surface 51, bottom surface 52 and second later surface 53 of the
runner core 20 can vary from 0.001 inches to 0.5 inches, and may
preferably be about 0.05, 0.1, 0.2, 0.3, or 0.4 inches. Of course,
a thickness z along the bottom surface can be thicker than a
thickness z along the lateral surfaces, if a weight on the deck 10
required such thickness. The thickness of the shell layer 50 all
around the runner cores and edge portions of the deck can be
adjusted according to different requirements. The shell 50 can be
adhered to an extensive surface of the sheet material at a top
and/or bottom of the deck 10, while protecting the lateral surface
56 of the edge portion 14. The distance between the outer surface
56 of the edge portion 14 of the deck 10 and the first lateral
surface 51 of the runner core 20 can be approximately between 1/4''
to 3'', and can preferably be approximately between 1/2'' to 2''.
The length of shell portions 65, 66, and 67 may be between 0.01 and
5 inches, preferably between 1/2 inch and 3 inches, and most
preferably between 3/4 inches and 2 inches.
[0038] The portion of the shell 50 along the upper surface 57 of
the edge portion 14 can be single-ply or of a lesser thickness than
the portion of the shell along the outer surface 56 of the edge
portion 14, so that any object or weight that is placed on the top
surface 11 of the deck 20, if placed over the upper surface 57 of
the edge portion 14, is not lop-sided, and yet will still provide a
protective covering. The shell, or any of the facings, in any of
the embodiments described herein may be scored at to improve
folding about any of the edges over which the shell
bends/folds--for example on the deck 10 or the runners 200, 300,
and 400.
[0039] FIG. 5 shows a broken up top cross-sectional view of the
runner core 20 along line V-V as shown in FIG. 4. The honeycomb
structure 80 of the runner core 20 is shown with the protective
shell 50 around it. The honeycomb structure 80 can have walls 60.
The honeycomb structure can have cells of six walls 60 as shown in
FIG. 5, having a hexagonal shape, or can have an octagonal shape as
well. Of course, the structure can also have 3-4 sides as well. The
honeycomb structure 80 can provide for plenty of air spaces 82
within or in between the walls 60 to provide for a low-density
honeycomb material, such that the honeycomb structure of the runner
core 20 is more crushable in comparison to the shell, while the
shell 50 is more dense. For example, the runner cores can comprise
a material having between 60%-90% airspace, and preferably more
than 70% airspace, and the shell 50 can comprise a material having
less than 25% airspace, and preferably less than 10% airspace.
[0040] The pallet structure of the preferred embodiment provides a
pallet capable of handling loads up to about 2000, 2250, or 2500
lbs. The pallet structure can be a lightweight material, such as
paper material, which can provide savings on shipping costs, and is
recyclable as it can be made of paper material. It is safe and easy
to handle compared to wooden pallets, which generally have nails
and splinters. The paper pallet structure also can eliminate import
restrictions on wood.
[0041] FIG. 6 shows a perspective view of another embodiment
according to the present disclosure. A pallet structure 600 can be
provided, having a deck 610 and a runner 612. The runner 612 can
include a core 620, or other internal support member, such as in
the above embodiments. The runner 612 is provided along an edge of
a pallet structure, but the its construction can also be used for
other runners of the pallet, whether near an edge or along a middle
portion of the deck 610.
[0042] The runner includes a protective shell 627, which is made of
a plurality of sheet layers. Protective layer 630 of the shell 627
can be constructed of similar material as used in the shell 50
described above and can be provided surrounding the core 620. In
the embodiment of FIG. 6, the protective layer 630 ends at or near
the deck 610, and preferably does not extend parallel to the deck
60. A connecting layer 632 of the shell 627, preferably an outer
layer, although alternatively the connecting layer can be an inner
layer in contact with the core, or a mid layer, extends from over
the shell to include supportive portions, such as flanges 635, that
are bent to cover a portion of the deck extending away from the
runner core 620, and which are preferably adhered to the lower
facing 637. Connecting layer 632 connects the shell to the deck,
and thus improves the robustness of the attachment between the
runner and deck, and helps prevent the runner from being knocked
off the deck. Preferably, the connecting layer 632 has bends
between portions that extend over a portion of the bottom and/or
sidewall of the deck 610, the side walls 615 of the runner 612, and
the bottom side 625 of the core 620, providing a connection between
these portions. The connecting layer 632 is preferably thinner than
the protective layer 630, and can be made of similar sheet material
as the facing on the deck 610 or sheets between the honeycomb
portions of the core 620. Both the connecting layer and the
protective layer can be made of multiple sheet layers, and
preferably individually and collectively provide a high-density
material, such as used in the embodiments above. Alternative shells
can be provided with thinner flanges than portions protecting the
runner core.
[0043] The shell 627 in the embodiment is constructed of two
pieces, each of which is Z-shaped to extend from flanges 635 to
where they form the bottom surface of the runner 621, under the
core 620. To ease manufacturing tolerances, the shell can be
discontinuous, such as in a lateral direction, having a gap 650
provided between the Z-shaped pieces, preferably remove from the
corners of the runner bottom, and most preferably near the center
of the bottom surface of the core. The gap 650 can have a width w1
of about between 1/32'' to about 1'', although larger and smaller
gaps can be used. Typically, width w1 is between about 1/20 to 1/2
of the runner width w2. The gap can have a length as long as the
length of the runner 620.
[0044] One having ordinary skill in the art should appreciate that
there are numerous shapes and sizes of the runners and deck for
which there can be a need or desire to load items thereon according
to exemplary embodiments of the present invention. Additionally,
one having ordinary skill in the art will appreciate that although
the preferred embodiments illustrated herein reflect a generally
flat and rectangular deck, with long rectangular runners, the
pallet structure can have a variety of shapes and sizes. The shell
can be made of various materials, such as a corrugated sheet
structure, as well as multiple layers of sheet material, or other
material. The runners and deck can also comprise various materials,
which can be of a less density or hardness than the shell
material.
[0045] As used herein, the terms "front," "back," and/or other
terms indicative of direction are used herein for convenience and
to depict relational positions and/or directions between the parts
of the embodiments. It will be appreciated that certain
embodiments, or portions thereof, can also be oriented in other
positions.
[0046] In addition, the term "about" should generally be understood
to refer to both the corresponding number and a range of numbers.
In addition, all numerical ranges herein should be understood to
include each whole integer within the range. While an illustrative
embodiment of the invention has been disclosed herein, it will be
appreciated that numerous modifications and other embodiments may
be devised by those skilled in the art. Therefore, it will be
understood that the appended claims are intended to cover all such
modifications and embodiments that come within the spirit and scope
of the present invention.
* * * * *