U.S. patent application number 14/528036 was filed with the patent office on 2015-05-07 for paperboard pallet.
The applicant listed for this patent is Liberty Diversified International, Inc.. Invention is credited to James A. Frautschi, Randy J. Lehner, Ronald L. Leino, Theodore G. Young.
Application Number | 20150122160 14/528036 |
Document ID | / |
Family ID | 53006037 |
Filed Date | 2015-05-07 |
United States Patent
Application |
20150122160 |
Kind Code |
A1 |
Frautschi; James A. ; et
al. |
May 7, 2015 |
PAPERBOARD PALLET
Abstract
A paperboard pallet is provided that includes first and second
cardboard stringers positioned substantially parallel to each
other. A space is formed between the first and second stringers. At
least a first deck board is attached to and positioned
substantially perpendicular to the first and second stringers. Both
the first and second stringers include a notch on their top sides.
Each notch on the top side of the first and second stringer is
sized to receive the first deck board, and is located so a first
side of the first deck board in each notch in the top side of the
first and second stringers is located substantially flush with the
first end of the first and second stringers.
Inventors: |
Frautschi; James A.;
(Lakeville, MN) ; Leino; Ronald L.; (Eden Prairie,
MN) ; Lehner; Randy J.; (Brooklyn Park, MN) ;
Young; Theodore G.; (Buffalo, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Liberty Diversified International, Inc. |
New Hope |
MN |
US |
|
|
Family ID: |
53006037 |
Appl. No.: |
14/528036 |
Filed: |
October 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14203042 |
Mar 10, 2014 |
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14528036 |
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61897987 |
Oct 31, 2013 |
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61776553 |
Mar 11, 2013 |
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61776588 |
Mar 11, 2013 |
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Current U.S.
Class: |
108/51.3 |
Current CPC
Class: |
B65D 2519/00378
20130101; B65D 2519/00333 20130101; B65D 2519/00288 20130101; B65D
2519/00318 20130101; B65D 2519/00298 20130101; B65D 2519/00308
20130101; B65D 2519/00273 20130101; B65D 2519/00343 20130101; B65D
2519/00323 20130101; B65D 2519/00089 20130101; B65D 19/0095
20130101; B65D 2519/00054 20130101; B65D 2519/00373 20130101; B65D
2519/00019 20130101; B65D 2519/00562 20130101; B65D 19/0012
20130101; B65D 19/0081 20130101; B65D 2519/00293 20130101 |
Class at
Publication: |
108/51.3 |
International
Class: |
B65D 19/00 20060101
B65D019/00 |
Claims
1. A paperboard pallet comprising: first and second stringers
positioned substantially parallel to each other; wherein each of
the first and second stringers is made of a plurality of bonded
sheets of cardboard; wherein a space is formed between the first
and second stringers; wherein each of the first and second
stringers has a top side, an underside, and a first end, wherein
the underside is located opposite the top side; at least a first
deck board attached to the first and second stringers and
positioned substantially perpendicular to the first and second
stringers; wherein both the first and second stringers include a
notch on their top sides; wherein each notch on the top side of the
first and second stringer is sized to receive the first deck board,
and is located so a first side of the first deck board in each
notch in the top side of the first and second stringers is located
substantially flush with the first end of the first and second
stringers; wherein both the first and second stringers include a
notch on their undersides; a second deck board; wherein each notch
on the underside of the first and second stringers is sized to
receive the second deck board, and is located so a first side of
the second deck board in each notch of the underside of the first
and second stringers is located substantially flush with the first
end of the first and second stringers; and a paper wrap is attached
to the underside and sides of the first and second stringers and
the second deck board, and spans the space formed between the first
and second stringers.
2. The paperboard pallet of claim 1, wherein the cardboard is
corrugated cardboard.
3. The paperboard pallet of claim 1, further comprising a third
stringer located in the space formed between the first and second
stringers, which creates a second space in addition to the first
space, wherein the space and the second space are each sized to
receive a forklift fork.
4. The paperboard pallet of claim 1, wherein both the first and
second stringers have a second end located opposite the first
end.
5. The paperboard pallet of claim 1, further comprising a second
deck board, wherein the second deck board is positioned
substantially parallel to and spaced apart from the first deck
board.
6. The paperboard pallet of claim 5, further comprising a second
notch on the top side of each of the first and second stringers,
wherein each second notch on the top side of the first and second
stringers is sized to receive the second deck board.
7. The paperboard pallet of claim 6, wherein the second deck board
is fitted in the second notch on the top side of each of the first
and second stringers, wherein the deck board is substantially flush
with the topside of the first and second stringers.
8. The paperboard pallet of claim 1, wherein the paper wrap is
selected from the group consisting of paper, kraft paper, and
cardboard.
9. The paperboard pallet of claim 1, wherein the paper wrap
includes first and second forklift openings that coincide with
forklift openings in the first and second stringers.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application to
U.S. patent application Ser. No. 14/203,042, filed Mar. 10, 2014,
entitled "Paperboard Pallet" and claims the benefit of U.S.
Provisional Application Ser. No. 61/897,987 filed Oct. 31, 2013,
entitled "Paperboard Pallet--3" and claims the benefit of U.S.
Provisional Application Ser. Nos. 61/776,553, filed Mar. 11, 2013,
entitled "Paperboard Pallet" and U.S. Provisional Application Ser.
No. 61/776,588, filed Mar. 11, 2013, entitled "Machine and Method
for Making a Corrugated Paperboard Pallet" which are hereby
incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to corrugated paper,
cardboard, and/or fiber board pallets, as well as a method for
making the same.
BACKGROUND AND SUMMARY
[0003] Conventional pallets are typically made of wood or plastic.
Wood pallets consist of a plurality of spaced apart wood boards or
stringers that are sandwiched between a plurality of spaced apart
deck boards. These deck boards generally run parallel to each other
and perpendicular to the stringers. When all the deck boards and
stringers are nailed together, a secure platform is created that
accommodates cargo, product, and other materials. In such wood
pallet designs, spaces exist between the upper and lower deck
boards that sandwich the stringers. These spaces are sized to
accommodate forklift blades so that the products or materials
setting on the pallet can all be lifted at one time when the
forklift lifts the pallet.
[0004] The present disclosure is directed to a pallet made of
cardboard or paperboard. Illustratively, the pallet may be made of
corrugated cardboard. In one embodiment, a pallet may be made of
cardboard stringers and deck boards. The stringers may be made of a
composite of corrugated cardboard strips laminated together with
glue to create a lightweight rigid structure. Similarly, the deck
boards may be made from laminated strips of cardboard. The
paperboard pallet provides a lightweight, high strength, solution
for packing and/or warehousing product where a strong pallet is
necessary but wood cannot be used because of issues such as insects
in the pallet wood. For example, the food industry requires much of
its packaged food product be stored and shipped on pallets, but
insects in wood pallets pose a contamination risk. A paperboard
pallet solution serves the pallet need, but does not have the issue
with insects that a natural wood has.
[0005] Another illustrative embodiment of the present disclosure
provides a paperboard pallet. The paperboard pallet comprises first
and second stringers positioned substantially parallel to each
other. Each of the first and second stringers is made of a
plurality of bonded sheets of cardboard. A space is formed between
the first and second stringers. Each of the first and second
stringers has a top side, an underside, and a first end. The
underside is located opposite the top side. At least a first deck
board attached to the first and second stringers and positioned
substantially perpendicular to the first and second stringers. Both
the first and second stringers include a notch on their top sides.
Each notch on the top side of the first and second stringer is
sized to receive the first deck board. Each notch is also located
so a first side of the first deck board in each notch in the top
side of the first and second stringers is located substantially
flush with the first end of the first and second stringers. Both
the first and second stringers include a notch on their undersides.
A second deck board is provided as well. Each notch on the
underside of the first and second stringers is sized to receive the
second deck board. These underside notches are also located so a
first side of the second deck board is located substantially flush
with the first end of the first and second stringers. A paper wrap
is attached to the underside and sides of the first and second
stringers, the second deck board, and spans the space formed
between the first and second stringers.
[0006] In the above and additional embodiments, the paperboard
pallet may further comprise: the cardboard is corrugated cardboard;
a third stringer located in the space formed between the first and
second stringers, which creates a second space in addition to the
first space, wherein the space and the second space are each sized
to receive a forklift fork; both of the first and second stringers
have a second end located opposite the first end; a second deck
board positioned substantially parallel to and spaced apart from
the first deck board; a second notch on the top side of each of the
first and second stringers, wherein each second notch on the top
side of the first and second stringers is sized to receive the
second deck board; the second deck board is fitted in the second
notch on the top side of each of the first and second stringers,
wherein the deck board is substantially flush with the topside of
the first and second stringers; the paper wrap is selected from the
group consisting of paper, kraft paper, and cardboard; the paper
wrap includes first and second forklift openings that coincide with
forklift openings in the first and second stringers.
[0007] Additional features and advantages of the paperboard pallet
will become apparent to those skilled in the art upon consideration
of the following detailed description of the illustrated embodiment
exemplifying the best mode of carrying out the paperboard pallet as
presently perceived.
BRIEF DESCRIPTION OF DRAWINGS
[0008] The present disclosure will be described hereafter with
reference to the attached drawings which are given as non-limiting
examples only, in which:
[0009] FIG. 1 is a perspective view of an illustrative embodiment
of a paperboard pallet;
[0010] FIG. 2 is a side view of the paperboard pallet of FIG.
1;
[0011] FIG. 3 is a side exploded view of the paperboard pallet of
FIG. 1;
[0012] FIG. 4 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0013] FIG. 5 is a side view of the paperboard pallet of FIG.
4;
[0014] FIG. 6 is a side exploded view of the paperboard pallet of
FIG. 4;
[0015] FIG. 7 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0016] FIG. 8 is a side view of the paperboard pallet of FIG.
7;
[0017] FIG. 9 is a side view of a stringer portion of the
paperboard pallet of FIG. 7;
[0018] FIG. 10 is a front view of the paperboard pallet of FIG.
7;
[0019] FIG. 11 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0020] FIG. 12 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0021] FIG. 13 is a front partially disassembled view of the
paperboard pallets of either FIG. 11 or 12;
[0022] FIG. 14 is a front view of the pallet of either FIG. 11 or
12;
[0023] FIG. 15 is an isolated view of a folded sheet that surrounds
the paperboard pallet of either FIG. 11 or 12;
[0024] FIG. 16 is a top view of the paperboard sheet of FIG. 11 in
an unfolded configuration;
[0025] FIG. 17 is a top view of the paperboard sheet of FIG. 12 in
unfolded configuration;
[0026] FIG. 18 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0027] FIG. 19 is an isolated front view of a folded sheet for use
on the paperboard pallets of either FIG. 11, 12, or 18;
[0028] FIG. 20 is a top view of the paperboard pallet of FIG.
18;
[0029] FIG. 21 is a perspective view of an illustrative embodiment
of an unassembled stringer composite;
[0030] FIG. 22 is a perspective view of another illustrative
embodiment of a paperboard pallet;
[0031] FIG. 23 is a perspective view of a stringer used for the
paperboard pallet in FIG. 22;
[0032] FIGS. 24A through C are perspective views of a deck board
being wrapped;
[0033] FIG. 25 is a top view of a liner;
[0034] FIG. 26 is a side view of a flute that forms a deck board;
and
[0035] FIG. 27 is a top view of a paperboard sheet in unfolded
configuration.
[0036] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplification set out
herein illustrates embodiments of the paperboard pallet and method
of making, and such exemplification is not to be construed as
limiting the scope of the paperboard pallet and method of making in
any
DETAILED DESCRIPTION OF THE DRAWINGS
[0037] A perspective view of an illustrative embodiment of a
paperboard pallet 2 is shown in FIG. 1. Pallet 2 includes
parallel-spaced and spaced apart stringers 4, 6, and 8 sized as
desired in relation to a desired pallet size. Attached transversely
to the top surface of stringers 4, 6, and 8 are deck boards 10 and
leading-edge deck boards 12 on the top side 14 of stringers 4, 6,
and 8. It is appreciated in this embodiment that deck boards 10 and
12 are essentially flush with the top side 14 of stringers 4, 6,
and 8. As shown in this view, the stringers 4, 6, and 8 may each
include a plurality of forklift slots 16 and 18 which are
illustratively in communication with spaces 20 and 22 also located
adjacent stringers 4, 6, and 8, respectively. It is appreciated
that forklift slots 16 and 18 are configured to receive the blades
(not shown) of a standard forklift. On the underside of stringers
4, 6, and 8 are underside deck boards 24, 26, and 28. It is
appreciated that end deck boards 24 and 28 form a leading edge on
the underside of pallet 2 just as top deck boards 12 form leading
edges on the top side of pallet 2. It is also appreciated from this
view how the deck boards and stringers are spaced apart in similar
fashion to a conventional pallet to provide an air of familiarity,
yet are not made of solid wood boards.
[0038] A side view of pallet 2 is shown in FIG. 2. This view shows
the shape of stringer 4 (like stringers 6 and 8) and how top deck
boards 10 and 12, as well as underside deck boards 24, 26, and 28,
have a top surface that is flush with top side 14 and bottom side
30 of stringer 4. Having deck boards in this configuration helps
resist compression or crushing forces on the stringers when a load
is applied to the deck boards. This view also includes stringer
forklift cutouts 16 and 18. In an illustrative embodiment, the
cutouts have a curved radius such as a 3 inch radius. This may help
distribute the forces when a forklift blade lifts on the pallet,
thereby moving the weaker point to a stronger part of the stringer.
It is further appreciated that the laminations of corrugated
cardboard may be 500# double wall corrugated board. In addition,
the number of stringers on the top and the bottom may be more or
less than what is shown herein, depending on the needs for the
pallet.
[0039] A side exploded view of pallet 2 is shown in FIG. 3. This
view demonstrates how notches 32 and 34 are cut into the top and
bottom of the stringers, such as stringer 4 shown, so the deck
boards maintain a flush appearance with the top side 14 and
underside 30 of pallet 2. It is also appreciated that the
dimensions of the stringers and deck boards may be varied,
depending on the needed size of the pallet.
[0040] A perspective of another illustrative embodiment of a
paperboard pallet 28 is shown in FIG. 4. It is appreciated that the
use and configurations of the deck boards and stringers can be
modified. Here, stringers 40, 42, and 44 include flush mounted deck
boards 10 and 12 and include forklift slots 16 and 18 in
communication with spaces 20 and 22. This embodiment also has a
bottom sheet 46 that spans stringers 40, 42, and 44 on the
underside of paperboard pallet 28. Bottom sheet 46 may help in
resisting the bottom the stringers 40, 42, and 44, from separating
during racking. Also, because as shown, bottom sheet 46 extends to
the forklift holes 16 and 18, the sheet may also make these holes
stronger. It is also appreciated that the forklift holes may be
included on all sides of the pallet, including stringer 42. Spaces
20 and 22 may also have open ends so that a forklift may lift the
pallet from any direction with respect to the pallet.
[0041] A side view of pallet 28 is shown in FIG. 5. This view shows
how top deck boards 10 and 12 are substantially flush with the top
surface of the stringers 40, 42, and 44. Also shown is corrugated
bottom sheet 46 attached to the underside of stringers 40, 42, and
44. This view also shows forklift openings 16 and 18.
[0042] A side exploded view of pallet 28 is shown in FIG. 6. This
view demonstrates the versatility in using deck boards and sheets.
Similar to the prior embodiment, notches 48 may be cut into the
stringer to create space for deck boards 10 and 12 to fit in the
flush configuration. Bottom sheet 46 is attached to the underside
of the stringers.
[0043] A perspective view of another illustrative embodiment of a
paperboard pallet 50 is shown in FIG. 7. This embodiment includes
top deck boards 10 and 12 sitting flush on stringers 52, 54, and 56
having similar spaces and openings like that previously discussed.
This embodiment also has a bottom sheet 58 that spans the stringers
52, 54, and 56 to provide the bottom surface of pallet 50. In this
embodiment, however, forklift holes 60 and 62 are disposed in
stringers 52, 56, and 58, rather than being a cutout on the bottom
of the stringers, as shown with the stringers in FIGS. 1 and 4.
[0044] A side view of pallet 50 is shown in FIG. 8. This view
demonstrates how forklift holes 60 and 62, being disposed within
stringer 52, are in contrast to the prior embodiments. Despite this
change, pallet 50, and particularly stringer 52 (along with
stringers 54 and 56) still accommodates deck boards 12 and 10 along
with bottom sheet 58.
[0045] A side view of stringer 52 is shown in FIG. 9. This view
demonstrates how the silhouette of stringer 52, as well as
stringers 54 and 56, accommodates both notches 64, as well as
forklift holes 60 and 62.
[0046] A front view of pallet 50 is shown in FIG. 10. This view
helps demonstrate how stringers 52, 54, and 56 in combination with
deck boards, such as deck boards 10 and 12 and bottom sheet 58,
create a pallet that is familiar in its configuration, is
lightweight, and durable while not being made of wood. This view
also shows spaces 66 and 68 that accommodate forklift blades, as
discussed in other embodiments such as spaces 20 and 22 of pallet
2. It is further appreciated that the deck boards may be made from
a composite of many strips of corrugated cardboard laminated
together with adhesives. Also illustratively, paper, such as craft
paper, may be wrapped around the deck boards.
[0047] A perspective view of another illustrative embodiment of
paperboard panel 70 is shown in FIG. 11. This embodiment includes
stringers 72, 74, and 76 that are spaced apart from each other
similar to prior embodiments, but are now wrapped in a folder-style
corrugated sheet 78 that forms both the top deck and bottom of
pallet 70.
[0048] A perspective view of another illustrative embodiment of a
paperboard pallet 80 is shown in FIG. 12. Pallet 80 differs from
pallet 70 in that the wrapped sheet 82 is used instead of wrapped
sheet 78. As shown in this embodiment, wrapped sheet 82 is folded
around stringers 84, 86, and 88 and does not include any openings
on the top side surface. This provides a smooth continuous surface
area for applications having such a need.
[0049] A front view of pallet 80 (like pallet 70) demonstrating how
wrapped sheet 82 folds around stringers 84, 86, and 88, is shown in
FIG. 13. In this embodiment, wrapped sheet 82 folds around to the
underside of pallet 80 and includes end portions 90 and 92 which
fold upward and adjacent one side of center stringer 86. In the
embodiment shown, wrapped sheet 82 folds around the parallel spaced
apart stringers 84, 86, and 88. Ends 90 and 92 fold up and are
glued against side 94 of stringer 86, as also shown in the end view
of FIG. 14. It is appreciated that in this configuration wrapped
sheet 82 creates an offset positioning, as demonstrated by the
front view of folded wrapped sheet 82 in FIG. 15.
[0050] Top views of cardboard sheets 78 and 82 in unfolded
configurations are shown in FIGS. 16 and 17, respectively. As shown
in FIG. 16, sheet 78 includes cut openings 122. Fold lines 124,
126, and 128 may be either scored or otherwise defined as the
location where sheet 78 is folded to wrap around the stringers.
Also, cut into sheet 78 are forklift openings 130. In the
illustrative embodiment, underside openings 132 are cut in sheet 78
(and 82) to reduce material and gain access to the interior of the
pallet. In similar fashion, sheet 82 includes score lines 124, 126,
and 128 on each side, so sheet 82 may be wrapped around the
stringers. In this embodiment, however, there are no cut openings
like openings 122 in sheet 78. Instead, the top side of sheet 82 is
a continuous surface. There are forklift openings 130 cut as shown,
and end portions 90 and 92 are formed by score lines 128 also
shown. It is appreciated that the cutouts may be useful even though
they might reduce some strength. In certain instances, fire codes
require holes in the pallets so water may filter through the
pallets from top to bottom. In addition, the cutouts may reduce
slippage on the surface. Alternatively, the deck surface may
receive an anti-slick agent to reduce slippage. Further, the single
sheet may be a 500# double-wall folded sheet of corrugated
cardboard.
[0051] A perspective view of another illustrative embodiment of a
paperboard pallet 100 is shown in FIG. 18. Paperboard pallet 100 is
similar to pallet 80 from FIG. 12, but with the addition of deck
boards 102 placed on the top. This embodiment includes stringers
84, 86, and 88, like the prior embodiment.
[0052] A front view of a partially folded wrapped sheet 82 (or
wrapped sheet 78) is shown in FIG. 19. This view demonstrates how
wrapped sheet 82 is folded to fit around the pallet forming an
outer skin.
[0053] A top view of pallet 100 with deck boards 102 attached on
top is shown in FIG. 18. It is appreciated that the horizontal
corrugation provided by folded sheet 82, for example, may improve
stringer strength. The stringers may also have improved strength by
the addition of the corrugated deck boards 102 attached as shown.
Such deck boards may also be attached to the underside (not shown)
in similar configuration to that shown in FIG. 20.
[0054] A perspective view of an unassembled stringer 118 is shown
in FIG. 20. In this illustrative embodiment, the aforementioned
stringers are a composite of corrugated cardboard sheets,
sandwiched together, and glued to form a high strength, low weight
beam. Unassembled stringer 118 shows how in not all cases the
sheets of cardboard need to be completely separate. In this case,
score lines 120 may be made at regular intervals and the sheet cut
into the desired stringer shape. In an accordion-like fashion, the
cardboard may be folded into the stringer. The sheets are then
glued together to form the final stringer board. Also shown are
cutouts 122 that form the forklift holes in the stringers, as
previously discussed in the prior embodiments.
[0055] Another illustrative embodiment of the present disclosure
provides a paperboard pallet 200. Paperboard pallet 200 includes
parallel-spaced apart stringers 204, 206, and 208. It is
appreciated that they are sized as desired based on its use. Deck
boards 210 extend transversely to the orientation of the stringers
on the top and bottom surfaces. Leading edge deck boards 212 and
214 are similar construction to deck boards 210 except they are
located on the top and bottom ends of paperboard pallet 200,
respectively. Each deck board fits into a notch 215(see also FIG.
23) so that they become flush with the top surface 217 of each of
the stringers 204, 206, and 208, providing a level top surface
similar to that described in previous embodiments. Paperboard
pallet 200 also includes forklift slots 216 and 218 formed in at
least stringers 204 and 208. It is appreciated that stringer 206
may include forklift slots 216 and 218, as well to maintain
modularity of assembling the pallet and/or because the forklift
blades extend through the entire length of the pallet. It is
appreciated that slots 216 and 218 are also formed in paperboard
wrap 220 (see also FIG. 27). It is appreciated that bottom 222 of
paperboard wrap 220 is attached hereto and sides 226 are attached
to the sides of the stringers capturing the structures of the deck
board. It is appreciated that an adhesive may be applied to
stringers 204 and 208, as well as at the bottom and top deck boards
to create a secure attachment between the pallet and paperboard
sheet 220. This U-shape wrap on the pallet, as shown, may be used
in an unsupported rack system in warehouses. The forces on the
pallet may be better distributed throughout same by virtue of the
U-shape wrap. Additionally, the U-shape wrap of sheet 220 may also
prevent the stringers from collapsing or kicking out at the sides
when substantial weight is applied.
[0056] A perspective view of an illustrative embodiment of
stringers 204, 206 or 208 is shown in FIG. 23. This view shows the
configuration of the stringer to accommodate the deck boards and
forklift slots. As shown, deck boards are configured to fit into
notches 215 on both tops of the stringer. In addition, lower
notches 215 on the underside of the stringer may be employed to
receive a deck board on the underside of the pallet. Employing
underside deck boards increases the pallet's ability to withstand
the rigors of moving on conveyors, as well as having added strength
for racking. The dimensions of these stringers may be similar to
those described for the previous embodiments and may include about
10 strips of corrugated board, or other paper glued together. The
paper may also be scored in an accordion-like manner, as shown in
FIG. 21. In an illustrative embodiment, the stringers may be about
477/8 inches long by 51/2 inches tall with a tolerance of about +
or - 1/16 of an inch. Similar to prior embodiments, these stringers
may be cut sheets of boards, such as corrugated or like board,
laminated together using adhesive or other fastening material to
provide a stringer with the appropriate strength and stiffness.
[0057] The several perspective views shown in FIGS. 24A through C
include deck boards 210 or 212 wrapped with a craft-type paper
wrapping 228. It is appreciated that deck board 210 and 212 may be
formed by a plurality of paperboard, such as corrugated cardboard
flutes 230 (see also FIG. 26) that are laminated together. In an
illustrative embodiment, approximately 19-21 layers of these flutes
230 may be laminated together to form a deck board of desired
width. In a further illustrative embodiment, the deck board may be
393/4 inches long by 51/8 inches wide and about 1 inch tall. It is
further appreciated that more flutes may be used depending on the
desired use. It is also appreciated that in one embodiment the
strips may be made by making multiple slices along the top surface
of the sheet of corrugated cardboard which are then folded in an
accordion-type manner (see FIG. 21 with respect to the stringer) to
form the laminated deck board. As shown in FIGS. 24B and C, glue
may be applied to a sheet of craft paper that can then wrap around
at least three sides of the deck board. In another illustrative
embodiment the wrap may wrap around all four sides of the deck
board.
[0058] A top view of an unfolded liner 228 is shown in FIG. 25.
This liner is configured to wrap around the deck board, as
previously discussed. It is also appreciated that this size is
configurable to match the size of the deck board.
[0059] A side view of an illustrative flute 230 is shown in FIG.
26. It is appreciated that the illustrative flute shape and size is
illustrative and indicative of the final shape. It is appreciated,
as discussed previously, that the flutes may be created in any
variety of manners, including scoring cardboard and folding in an
accordion-like fashion.
[0060] A top view of a paperboard shape wrap 220 is shown in FIG.
27. As discussed with respect to paperboard pallet 200 in FIG. 22,
sheet 220 wraps around the bottom and side portions of pallet 220
in a U-shape configuration assisting in providing strength to the
overall pallet. This embodiment, as shown in FIG. 27, includes
mirror images of sheet 220 so that it may be folded over, thereby
providing additional strength by doubling up on the sheet when
forming into its U-shape configuration. Additionally, holes 234 may
be formed in sheet 220 for use with a pallet jack.
[0061] Although the present disclosure has been described with
reference to particular means, materials, and embodiments, from the
foregoing description, one skilled in the art can easily ascertain
the essential characteristics of the present disclosure and various
changes and modifications may be made to adapt the various uses and
characteristics without departing from the spirit and scope of the
present invention as set forth in the following claims.
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